Van's Aircraft RV-12 User manual

Revision: 9.3 Date: 12/18/18
RV-12
MAINTENANCE MANUAL
Aircraft Serial Number: ___________________________

Rev: 9.3 12/18/18
ii
REVISION SUMMARY
CHAPTER
REVISION
DATE
COVER PAGE
9.3
12/18/18
ii
9.3
12/18/18
iii
6
07/16/16
iv-viii
7
12/18/18
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12/18/18
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04/16/10
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5
12/18/18
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12/18/18
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6
12/18/18
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4
07/16/16
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2
04/03/14
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5
12/18/18
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6
12/18/18
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1
04/16/10
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07/16/16
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07/16/16
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04/03/14
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07/16/16
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12/18/18

Rev: 607/16/16
iii
OWNER/OPERATOR RESPONSIBILITIES
For continued airworthiness of an RV-12 aircraft, the owner/operator must comply with
the following requirements as dictated in ASTM F 2295 Section 5.
Each owner/operator of an RV-12 shall read and comply with the maintenance
manual and continued airworthiness information and instructions provided by
Van's Aircraft Inc.
Each owner/operator of an RV-12 shall provide Van's Aircraft Inc. with up to
date contact information so that Van's Aircraft may send the owner/operator
supplemental notification bulletins.
The owner/operator of an RV-12 shall notify Van's Aircraft Inc. of any safety of
flight issue or significant service difficulty upon discovery using the Feedback
Form provided in the Maintenance Manual.
The owner/operator of an RV-12 shall comply with all Van's Aircraft Inc. issued
notices of corrective action and comply with all applicable aviation authority
regulations in regard to maintaining the airworthiness of the LSA. Notices of
corrective action are published on the Van’s Aircraft web site RV-12 Service
Information Page. Or go to http://www.vansaircraft.com/public/service-rv12.htm
An owner of an RV-12 shall ensure that any needed corrective action be
completed as specified in a notice, or by the next scheduled annual
inspection.
Should an owner/operator not comply with any mandatory service requirement
the RV-12 shall be considered not in compliance with applicable ASTM
standards and may be subject to regulatory action by the presiding aviation
authority.

Rev: 7 12/18/18
iv
TABLE OF CONTENTS
CHAPTER 1- GENERAL
INTRODUCTION ................................................................................................................. 1-1
Purpose....................................................................................................................... 1-1
Summary..................................................................................................................... 1-1
Scope .......................................................................................................................... 1-2
Replacement Parts...................................................................................................... 1-3
Method ........................................................................................................................ 1-3
APPLICABLE THROUGHOUT................................................................................................ 1-4
General Safety ............................................................................................................ 1-4
Safety of Flight Reporting Procedure .......................................................................... 1-5
Helpful Terminology .................................................................................................... 1-5
Abbreviations .............................................................................................................. 1-6
Units ............................................................................................................................ 1-7
TOOLS AND EXPENDABLES ................................................................................................ 1-8
ENGINE.......................................................................................................................... 1-12
LUBRICATIONS AND CAPACITIES ....................................................................................... 1-13
Engine Oil.................................................................................................................. 1-13
Brake Fluid ................................................................................................................ 1-13
Engine Coolant.......................................................................................................... 1-14
Fuel ........................................................................................................................... 1-14
Tire Pressures........................................................................................................... 1-14
Torque Values ........................................................................................................... 1-15
GENERAL PROCEDURES.................................................................................................. 1-16
Lifting & Supporting the fuselage .............................................................................. 1-16
WEIGHT AND BALANCE .................................................................................................... 1-18
EQUIPMENT LIST ............................................................................................................ 1-21
CHAPTER 2- SERVICE SCHEDULE ............................................................................... 2-1
OVERVIEW ....................................................................................................................... 2-1
CHAPTER 3- INSPECTION.............................................................................................. 3-1
OVERVIEW ....................................................................................................................... 3-1
INSPECTION DESCRIPTION ................................................................................................. 3-3
Pre-inspection / Post-inspection.................................................................................. 3-3
Cockpit ........................................................................................................................ 3-5
Radio........................................................................................................................... 3-7
Optional Equipment..................................................................................................... 3-7
Emergency Locator Transmitter .................................................................................. 3-7
Propeller...................................................................................................................... 3-7

Rev: 7 12/18/18
v
Engine ......................................................................................................................... 3-8
Firewall Forward.......................................................................................................... 3-8
Fuselage ................................................................................................................... 3-10
Landing Gear ............................................................................................................ 3-11
Wing / Center Section/AOA ...................................................................................... 3-12
Rear Spar Doubler .................................................................................................... 3-13
Empennage............................................................................................................... 3-14
Angle-Of-Attack System ............................................................................................ 3-17
Paperwork ................................................................................................................. 3-17
CHAPTER 4 - STRUCTURAL REPAIRS ......................................................................... 4-1
OVERVIEW ....................................................................................................................... 4-1
MINIMUM CERTIFICATION................................................................................................... 4-2
CHAPTER 5 - STRUCTURES .......................................................................................... 5-1
OVERVIEW ....................................................................................................................... 5-2
FUSELAGE........................................................................................................................ 5-2
WING AND FLAPERON ....................................................................................................... 5-4
EMPENNAGE..................................................................................................................... 5-6
LANDING GEAR................................................................................................................. 5-8
FAIRINGS -WHEEL AND GEAR LEG..................................................................................... 5-10
SERVICE ........................................................................................................................ 5-12
CHAPTER 6 - FLIGHT CONTROLS................................................................................. 6-1
OVERVIEW ....................................................................................................................... 6-2
SERVICE .......................................................................................................................... 6-3
CHAPTER 7 - BRAKE SYSTEM ...................................................................................... 7-1
OVERVIEW ....................................................................................................................... 7-2
SERVICE .......................................................................................................................... 7-2
CHAPTER 8 - ELECTRICAL SYSTEM ............................................................................ 8-1
OVERVIEW ....................................................................................................................... 8-2
SERVICE .......................................................................................................................... 8-4
CHAPTER 9 - INSTRUMENTS & AVIONICS ................................................................... 9-1
OVERVIEW ....................................................................................................................... 9-2
PITOT &STATIC ................................................................................................................ 9-3
SERVICE .......................................................................................................................... 9-4

Rev: 7 12/18/18
vi
CHAPTER 10 - UTILITY SYSTEMS ............................................................................... 10-1
OVERVIEW ..................................................................................................................... 10-2
HEAT ............................................................................................................................. 10-2
VENTILATION .................................................................................................................. 10-3
SERVICE ........................................................................................................................ 10-4
CHAPTER 11 - PROPELLER......................................................................................... 11-1
OVERVIEW ..................................................................................................................... 11-2
SERVICE ........................................................................................................................ 11-2
Prop & Hub............................................................................................................... 11-3
CHAPTER 12 - FIREWALL FORWARD......................................................................... 12-1
OVERVIEW ..................................................................................................................... 12-2
Engine ...................................................................................................................... 12-3
SERVICE ........................................................................................................................ 12-3
CHAPTER 13 - FUEL SYSTEM...................................................................................... 13-1
OVERVIEW ..................................................................................................................... 13-2
Fuel System Schematic............................................................................................ 13-3
SERVICE ........................................................................................................................ 13-3
CHAPTER 14 - EXHAUST SYSTEM.............................................................................. 14-1
OVERVIEW ..................................................................................................................... 14-2
SERVICE ........................................................................................................................ 14-4
CHAPTER 15 - PAINTING AND COATINGS ................................................................. 15-1
OVERVIEW ..................................................................................................................... 15-2
SERVICE ........................................................................................................................ 15-3
CHAPTER 16 - TROUBLESHOOTING .......................................................................... 16-1
CHAPTER 17 - FEEDBACK & REPLACEMENT PARTS .............................................. 17-1
REPORTING METHODS .................................................................................................... 17-1
REPLACEMENT PARTS..................................................................................................... 17-2
SUBSTITUTE PARTS ........................................................................................................ 17-3
CHAPTER 18 - SUPPLEMENT ...................................................................................... 18-1
SERVICE SCHEDULE........................................................................................................ 18-3
INSPECTION CHECKLIST .................................................................................................. 18-7
3-VIEW ........................................................................................................................ 18-25
FEEDBACK FORM .......................................................................................................... 18-27

Rev: 7 12/18/18
vii
CHAPTER 19 - GLOSSARY........................................................................................... 19-1
CHAPTER 20 - INDEX.................................................................................................... 20-1
NOTE: Pages 1-21 and 1-22 correspond to a particular EFIS installation.
Please remove all pages that do not correspond to your EFIS.
Specific EFIS type is noted next to the page number.

Rev: 7 12/18/18
viii
TABLE OF ILLUSTRATIONS
Figure 1: Tools .................................................................................................................. 1-9
Figure 2: Oil Viscosity...................................................................................................... 1-13
Figure 3: Lifting and supporting....................................................................................... 1-17
Figure 4: Remove for inspection ....................................................................................... 3-4
Figure 5: Control Stops ..................................................................................................... 3-6
Figure 6: Rivet Inspection................................................................................................ 3-10
Figure 7: Wing Retention Pin Bushing............................................................................. 3-13
Figure 7.1: Inspect Rear Spar Doubler............................................................................ 3-14
Figure 8: Rudder Stop..................................................................................................... 3-15
Figure 9: Fuselage ............................................................................................................ 5-3
Figure 10: Wing and Flaperon........................................................................................... 5-4
Figure 11: Empennage...................................................................................................... 5-6
Figure 12: Landing Gear ................................................................................................... 5-8
Figure 13: Nose Wheel and Gear Leg Fairings ............................................................... 5-10
Figure 14: Main Wheel Fairings ...................................................................................... 5-11
Figure 15: Flaperon hinge ............................................................................................... 5-18
Figure 16: Extracting the DW4K2X bearing..................................................................... 5-20
Figure 16.1: Rear Spar Doubler Replacement ................................................................ 5-24
Figure 17: Locking clip removal......................................................................................... 6-4
Figure 18: Tensioner barrel removal ................................................................................. 6-4
Figure 19: Torque tube lubrication .................................................................................... 7-4
Figure 20: Optional Wing Tip Lighting ............................................................................... 8-3
Figure 21: Fuse panel ....................................................................................................... 8-6
Figure 22: Trim/Servo assembly removal.......................................................................... 8-8
Figure 23: Pitch-trim servo removal................................................................................... 8-8
Figure 24: Stall warning ground ...................................................................................... 8-10
Figure 25: Snap Bushing................................................................................................. 8-13
Figure 26: Rotax 912ULS................................................................................................ 12-3
Figure 27: Carburetor Overview ...................................................................................... 12-8
Figure 28: Mixture Screw ................................................................................................ 12-9
Figure 29: Throttle Handle Idle Position ........................................................................ 12-10
Figure 30: Vacuum Gauge ............................................................................................ 12-11
Figure 31: Fuel Pressure Hose Flush.............................................................................. 13-9

Rev. 8
1–1
CHAPTER 1 - GENERAL
INTRODUCTION
PURPOSE
The purpose of this manual is to provide guidance to RV-12 owners, pilots,
mechanics, regulatory officials, and aircraft/component manufacturers that are certified
to perform maintenance, repairs, and alterations on the light sport aircraft covered in
this manual.
SUMMARY
This manual contains maintenance instructions for the RV-12 light sport aircraft.
The RV-12 is a single engine, fixed tricycle gear, full-cantilever monoplane. The two-
seat cockpit is enclosed with a tip-up windscreen/canopy. The occupants sit side-by-
side, aft of the engine and forward of the wing spar. Both of the wings are quick
removable. The flaperons remain with the wings and self-connect to the control linkage
when the wings are installed. The empennage consists of a vertical stabilizer, rudder
and stabilator with anti-servo/trim tab.
The airframe is a semi-monocoque aluminum structure, with some steel and
fiberglass parts. Fiberglass composite parts are used to finish some non-structural
portions of the aircraft.
The pilot and passenger board the aircraft from either side using the boarding
step and a reinforced area near the leading edge of the wing. The pilot is seated on the
left side (from within the cockpit) of the aircraft. A combination Electronic Flight
Information System (EFIS) and Engine monitoring System (EMS) with graphical user
interface is used to monitor and report flight and engine performance information to the
pilot.
The Rotax 912ULS 100 hp four cylinder engine is enclosed in a fiberglass
composite cowling at the front of the aircraft. Engine power is transferred via an integral
gearbox to the Sensenich composite propeller.
The pilot and the passenger both have full flight and ground controls. Pitch and
roll is controlled from either control stick. The control sticks are linked by push/pull rods
and torque tubes to the flaperons, and linked by cables to a stabilator. The flap lever
controls the flap function of the flaperons. Yaw is controlled using rudder pedals linked
by cables to a traditional rudder that is hinged to a fixed vertical stabilizer. The rudder
pedals have integrated left and right foot pedals that are used to independently control
the wheel brake on the corresponding side.

Rev. 8
1–2
SCOPE
• NOTE: This maintenance manual is intended to be used in conjunction with
the RV-12 Kit Assembly Instructions (KAI) when completing maintenance or
repair processes.
All of the service and maintenance requirements that are unique to the RV-12 S-
LSA are included in this manual. The general service and maintenance duties that are
common to standard aircraft still apply to the RV-12 regardless of the inclusion of those
requirements in this manual. All inspection and maintenance and all maintenance log
entries must be made in accordance with 14 CFR / FAR’s.
The manufacturers of third party components provide manuals that include
complete service and maintenance requirements that are specific to these components.
The current service and maintenance manuals from any third party manufacturer, such
as; engine, propeller, avionics, etc. always take precedence over the related content in
this manual. There are references to third party documentation in this manual, as well
as some supplementary information which is for convenience only. It is recommended
to refer directly to the manufacturer’s service manuals for complete service information
that is unique to applicable components.
The manufacturers that provide operating and/or maintenance manuals to use in
conjunction with this manual are as follows:
♦Rotax – engine
♦Sensenich – propeller
♦Matco – wheels and brakes
♦Dynon – EFIS / EMS
♦Garmin – EFIS / EMS, GPS and Nav/comm
♦TCW – Backup Battery
♦FlightCom – intercom
♦ACK – ELT
♦Artex – ELT
♦Odyssey – battery
♦Van’s Aircraft −RV-12 Kit Assembly Instructions (KAI).
The service and inspection portions of this manual indicate the minimum
certification requirements for a person doing maintenance or repairs on the RV-12.
Certification requirements for service and maintenance may vary around the world. It is
essential to determine the correct and legal maintenance and certification requirements
applicable to the area that the airplane is registered. The documents necessary to
determine these requirements for S-LSA in the United States are as follows:
♦RV-12 Maintenance Manual
♦ RV-12 Kit Assembly Instructions
♦ Federal Aviation Regulations for Light Sport Aircraft Maintenance Technicians
♦ Aircraft Inspection, Repair, and Alterations, AC 43.13.

Rev. 8
1–3
REPLACEMENT PARTS
The RV-12 KAI is the primary reference for replacement part information. Section
Four in the KAI is a directory of all part numbers with reference information of where to
find it within the main KAI manual. The documentation produced by third party parts
manufacturers (listed above) should be used as the primary reference for part
information for those components.
METHOD
The pages throughout this maintenance manual are numbered at the bottom with
the chapter number followed by a dash and the page number of the applicable chapter.
There are many cross-references in this manual. Cross-references within this manual
are made using the page numbers, unless otherwise specified. Following is an example
of a typical cross-reference to additional information within this manual. Example: When
there is additional information that is related to this sentence the cross-reference to that
page will be in parenthesis following the period. (1-2)
Chapter 1 will introduce general information that is helpful for using this manual.
General information includes manual introduction, general safety information,
notification methods, abbreviations, collective tool list, list of expendables, lubrication
and capacities and general procedures.
Chapter 2 introduces the service schedule checklist.
Chapter 3 provides an explanation of the annual/100 hour inspection checklist
including illustrations that clarify some checkpoints of the aircraft. Read Chapter 1–3
prior to performing the inspection, and use it as a reference during the inspection.
Chapter 4 and following begin with an illustration of the subject discussed, an
‘Overview’ of the chapter content and a list of ‘Components’. The 'Service' section,
where applicable, begins with a table of ‘Supplies’, which includes; ‘Tools’, ‘Expendable’
and ‘Replaceable’ parts. The service section provides instructions for ‘General’ removal,
replacement and installation that are acceptable for the owner or operator to perform.
The service section also includes instructions for ‘Service Schedule Procedures’ which
correspond to the items on the 'Service Schedule Checklist'. Each service section task
includes a table that summarizes the properties of the task.
The task summary table lists the Tools, Expendable, and replaceable items that
are task specific. Only tools specific to the immediate task will be listed. In cases that
another task must be done to complete the immediate task, the tools needed for the
other task will be given in the instructions that correspond to that task. Some
recommended tools will require other tools to be effective; for example: sockets will
require a ratchet; drill bits will require a drill. Unless otherwise specified the driving tool
is implied rather than listed. The table also includes the ‘Service Rating’ applicable to
the task, the ‘Minimum Certification’ required to perform the task legally, and ‘Additional
References’ that may be helpful or necessary to complete the task. Each hardware item
to be removed in the service instructions will be followed by the quantity (if greater than
one) in parenthesis. For example, an instruction step that requires the removal of one

Rev. 8
1–4
bolt, six washers and two nuts will appear as follows: 1. Remove the bolt, washers (6),
and nuts (2).
Chapter 16 offers direction for solving potential problems that may puzzle the
owner of any aircraft.
Chapter 17 provides instructions for reporting the discovery of anomalies that
could compromise the airworthiness of the aircraft.
Chapter 18 includes the inspection checklist, service schedule checklist and
other helpful documents.
APPLICABLE THROUGHOUT
GENERAL SAFETY
Safety must be considered the first priority when performing maintenance or
service on an aircraft or part. The content in this manual is only for use in a safe work
environment with all necessary safety equipment readily available and in use when
applicable.
Maintenance or repair classified in this manual as owner and SPC and in 14
CFR, FAR 43 Appendix 'A' can be done by an RV-12 owner or operator that possesses
a Sport Pilot certificate or higher.
An LSA repairman certificate with a maintenance rating or an FAA issued A&P
certificate are the minimum level of certification to perform line maintenance or repairs
and the annual condition inspection on an RV-12.
Prior to performing maintenance or repair always disconnect the negative (-)
battery cable from the battery.
The strength of an airframe designed using semi-monocoque construction relies
on both the skins and the skeleton for complete structural strength. If a skin has been
damaged, typically the underlying structure has also been damaged. Carefully inspect
any damage to assess the extent of the damage. If the damage is localized to just outer
skins, they can be removed and replaced. If inspection indicates that the substructure is
also damaged the aircraft manufacturer must be consulted for further assessment.
Every time hardware is removed it must be checked for signs of wear or fatigue.
Inspect the head, shank, and threads of bolts, and the edges and threads of nuts.
Locking hardware may only be used for one term of service. Safety wire, cotter pins,
lock washers and similar hardware are only reliable after one term of service. It is
permissible to reuse nylock and all steel style self-locking nuts if it is determined that the
self-locking feature has not been degraded. Always replace questionable hardware.
Operation in Extreme Conditions: Exposure to extreme climatic conditions,
including dust, salt, debris, bugs, will warrant frequent inspections of air filters, coolant
radiator, and oil cooler as defined in the Rotax maintenance manual. Frequent exposure
to extreme conditions or altitudes demands adjustment of the carburetor and cooling
system. Contact an authorized Rotax distributor for consultation.

Rev. 8
1–5
SAFETY OF FLIGHT REPORTING PROCEDURE
To maintain the highest level of safety and as dictated in ASTM F 2295 Section
5, the FAA requires, and Van’s Aircraft Inc. requests notification of any safety of flight
issue, or service or maintenance difficulties that could compromises the airworthiness of
the RV-12 aircraft. A feedback form is provided in the Supplement section of this
manual. Refer to Chapter 17 for a description of a valuable report and the
different reporting methods available.
HELPFUL TERMINOLOGY
▲
WARNING:
I
NDICATES AN ACTION NECESSARY TO PREVENT INJURY OR DEATH
.
■
CAUTION:
I
NDICATES AN ACTION NECESSARY TO PREVENT DAMAGE TO PARTS OR
PROPERTY.
●
NOTE:
P
ROVIDES VALUABLE ADDITIONAL INFORMATION
.
The Glossary provides definitions to many of the terms used throughout this manual.

Rev. 8
1–6
ABBREVIATIONS
A&P*
Airframe and Power-plant
Mechanic
Kph
Kilometers per hour
AKI
Anti-knock index (octane rating)
Kts
Knots
API
American Petroleum Institute
lb
U.S. pound
AST*
Anti-servo/trim tab
LL
Low-Lead
AVGAS
Aviation Gasoline
LSA
Light Sport Aircraft
C
Celsius
LSA-RM*
Light Sport Aircraft – Repairman
Maintenance rating
CG
Center of Gravity
ltr
Liter
CHT
Cylinder Head Temperature
m
meter
cm
Centimeter
Max
Maximum
CST*
Category specific training
mb
millibar
EFIS*
Electronic Flight Information
System
mi
Statute mile
EGT
Exhaust Gas Temperature
Min
Minimum
ELT*
Emergency Locating Transmitter
ml
Milliliters
EMS
Engine Monitoring System
mm
Millimeter
F
Fahrenheit
mph
miles per hour
FAA
United States Federal Aviation
Administration
naut mi
Nautical miles
FAR’s
Federal Aviation Regulations
Nm
Newton meters
fl. oz.
fluid ounce (U.S.)
OAT
Outside Air Temperature
ft
Feet
oz
Ounce
ft/lbs
Foot-Pounds
POH*
Pilot Operating Handbook
FWD
Forward
psi
Pounds per Square Inch
gal
Gallon
pt
Pint (U.S.)
GPS*
Global Positioning System
RON
Research Octane Test
HP
Horse Power
RPM
Revolutions Per Minute
ID
Inner Diameter
S-LSA*
Special Light Sport Aircraft
in
Inch (depending on context)
S/N
Serial Number
in²
Square inches
SAE
Society of Automotive Engineers
in/lb
Inch-Pound
SPC*
Sport Pilot Certified
KAI*
Kit Assembly Instructions
TT
Total Time
kg
kilogram
VDC
Voltage, Direct Current
kPa
Kilopascal
* -- See glossary for definition

Rev. 8
1–7
UNITS:
Speed:
1 mph
=
1.64 kph
=
0.869 kts
Distances:
1 in
=
2.54 cm
1 ft
=
12 in
=
0.305 m
1 mi
=
5,280 ft
=
1.61 km
1 naut mi
=
1.15 mi
=
1.85 km
Mass:
1 oz
=
28.3 grams
1 lb
=
16 oz
=
0.454 kg
Pressure:
1 psi
=
6.895 kPa
1 mb
=
0.1 kPa
Volume:
1.8 cubic in
=
1 fl. oz
=
29.57 ml
1 quart
=
2 pints
=
32 fl. oz
1 gal
=
8 pints
=
3.79 ltr
Torque:
=
1 in/lb
=
0.113 Nm
1 ft/lb
=
12 in/lb
=
1.356 Nm
Temperature:
(F-32)/1.8
=
(1.8 x C)+32

Rev. 8
1–8
TOOLS AND EXPENDABLES
There are many aircraft tool suppliers available. An Internet search can be conducted to
determine which supplier can provide the necessary tools
♦
Combination
wrenches:
1/4
5/16
11/32
 3/8
 7/16 (2)
 1/2
 9/16
 11/16
 1 1/2
♦ Ratchet
♦ Sockets:
5/16
11/32
 3/8
 7/16
 1/2
 9/16
 3/4
 1 1/2
 10 mm
 11 mm
 13 mm
♦
Allen wrenches:
3/16
1/4
5/16
4mm
5mm
6mm
8mm
♦Torque wrench
(in/lbs & ft/lbs)
♦ 5/8 or 16 mm
spark plug socket
♦ Screwdrivers:
 #2 Phillips
 #3 Phillips
 3/16 Flat Blade
♦ Power-drill
♦ #30 drill bit
♦ Blind rivet tool
♦ Straight edge
♦ Razor knife
♦ Flashlight
♦ Step ladder
♦ Wire cutters
♦ Battery charger
♦ Multi-meter
♦ Syringes
♦
Wooden dowels 1/2 - 1 inch dia.
and 1 1/2 - 1 3/4 in. dia.
♦ Oil Filter wrench
♦ Oil Filter cutter and mallet
♦ Two 25 in. padded stands
each rated to support a
minimum of 500 pounds
♦ Container (various sizes,
suitable for petroleum)
♦ 24-inch length of 1/2-inch I.D. fuel
hose
♦ Scouring pad or equivalent
♦ Sandpaper (various grades)
♦ Spark plug gap tool (wire type)
♦ Compression tester
♦ Magnifying Glass
♦ Small square
♦ Tire air pressure gauge
♦ Needle nose pliers
♦ 5-inch “C” clamp
♦ Terminal crimping tool
♦ Locking (vice grip style) pliers
♦ 2 1/2 x 3/16 bolt, washer, nut
♦ Vacuum gauge set
♦ Portable weight scale (tension type)
♦ Fire extinguisher
♦ Pump style oil can with hose
♦ Safety wire twisting pliers
●
NOTE:
T
OOLS DIFFER IN SIZE AND CONFIGURATION
.
T
HE FOLLOWING
ILLUSTRATIONS ARE ONLY EXAMPLES OF WHAT A TOOL MAY LOOK LIKE.
●
NOTE:
T
HIS TOOL LIST DOES NOT INCLUDE ALL OF THE TOOLS SUGGESTED FOR THE
INSPECTION PROCEDURES.
TOOLS

Rev. 8
1–9
Combination Wrenches
Ratchet
Screwdrivers
Sockets
Allen Wrenches
Gap Gauge
Oil Filter Cutter
Heavy Stands
Step Ladder
Oil Filter Wrench
Battery Charger
Multi-meter
Magnifying Glass
Square
Air Pressure Gauge
Figure 1

Rev. 8
1–10
Razor Knife
Flashlight
Needle-nose Pliers
C-clamp
Terminal Crimper
Wire Cutter
Locking Pliers
Blind Riveter
Power-drill
Hardware
Dual Vacuum Gauge
Tensile Weight Scale
Figure 1

Rev. 8
1–11
■
CAUTION:
R
EPLACEMENT PARTS MUST BE OF EQUIVALENT SIZE
,
TYPE AND
RATING AS THE ORIGINAL PARTS FROM THE MANUFACTURER.
EXPENDABLE
PARTS
PART NUMBER
Oil filter
Rotax 825 701
Copper crush ring (for drain plug)
Rotax 250010
Gas-5 O-ring gasket
GASKET GAS-345
Tire
U-5:00X5 Tire (any aircraft grade 5:00X5, 4 or 6
ply tire is acceptable.
Inner tube
U 5:00X5-6IT (any aircraft grade 5:00X5-6 inner
tube is acceptable)
Brake shoe linings
M66-106 (or equivalent)
Fuses
ATO/ATC ¼ “ blade style 1, 2, 3, 5, 7.5, 30 Amp
rating. All fuse values of 3 amp and higher are
required to have LED “blown fuse” indicators.
LUBRICANTS
RECOMMENDATION OR EQUIVALENT
Engine oil
As specified in latest Rotax documentation
Spray lubricant
LPS2 or Tri-Flow
Dry lubricant (candle wax, etc.)
TOOL BOELUBE PASTE
Wheel bearing grease
Aeroshell 22 or equivalent
Thread-lube
Loctite 567 or equivalent
Anti-seize compound, High temp
Loctite Anti-Seize or equivalent
Hydraulic fluid
MIL-H-5606A or MIL- PRF-83282
Air filter oil
EA K&N 99-5050 KIT
MISCELLANEOUS
RECOMMENDATION OR EQUIVALENT
Engine coolant
1:1 Water/Ethylene Glycol (refer to Rotax
engine documentation)
Safety wire
WIRE SAFETY .032
Fuel tank sealant
MC-236-B1/2 or MC-236-B2
Plexus Cleaner/Polish
CA CANOPY CLEANER
Cotter pins
MS24665-xyz
Plastic tie wraps
Non-specific
Wire terminals
Male & Female spade, splice, and ring
Blind rivets
LP4-3 (unless otherwise specified)
Grey touch-up paint
PAINT, TOUCHUP PGRAY
Cardinal gray #3607-GR-230
Primer
Any protective primer suitable for use on
aluminum and/or steel as appropriate
Decorative touch-up paint
From paint process

Rev. 8
1–12
ENGINE
●
NOTE:
T
HE ENGINE SPECIFICATION INFORMATION IS REFERENCED FROM THE
ROTAX 912 SERIES,OPERATOR’S MANUAL,OM REV.4.
SUMMARY
Make
Rotax 912 ULS
Displacement
1352 cc
Ignition
Ducati Double CDI
Carburetor
Bing
Rated Horsepower
100 Hp @ 5800 RPM
DESCRIPTION
The LSA covered by this manual will have a Rotax 912ULS power plant. The
power plant is an over-head valve four-stroke, horizontally opposed four-cylinder. The
cylinder heads are liquid cooled. The cylinder barrels are air-cooled. Dual constant
depression carburetors regulate the air/fuel mixture. The dual breaker-less, capacitor
discharge ignition system provides the electrical energy to the spark plugs.
For engine maintenance requirements and procedures refer to the Rotax Engine
Type 912 Series line maintenance and heavy maintenance manuals.