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~:. • • J / .. -.:'-'°· · - "THE QIIIGINM:

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1

,i~ (r~, - ;_.,.~·;~~~LY ··MANUAL

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@ppczr aircraft inc. QUALITY ASSURANC( ACCrrn:o

11/orlch i..vg.,, M.onufMlur.., °'UlltMghl """"'' DATE B-17-~ J__/.,,..,,-----
E.C.O. "'.1.J>-¼-
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·------·-----·-· -----·
•
TABLE OF CONTENTS

PG. PG.
ABOUTTHISMANUAL ................. ! STRUTASSY ...................... 33-37
INTRODUCTION ..................... II RIBINVERTING ................... 38-39
NICOSLEEVE GAUGE PROCEDURE ..... 111 WIREASSY ....................... 40-42
ANBOLT GAUGE. ................... IV SPOILERASSY .................... 43-46
RUDDERASSEMBLY ............. ! ••• 1-2 KINGPOSTASSY ..................... 47
ELEVATOR
.......................... 3 LANDINGGEAR ATTACHMENT ............ 48
STABILIZER ASSY ................. 4-5 ENGINERE-INSTALLATION ............. 48
TAILSKIDASSY .................. 6-7 FUELTANK ASSY ..................... 49
TAILGROUP ASSY ................... 8 HEATCUTTING VELCRO OOOR ........... 50
EXHAUSTHEADER ASSY ............... 9 TAILTOPLANE ATTACHMENT ....... -.... 51
ENGINEMOUNT ASSY ............. 10-11 IGNITIONWIRING/FUEL SYSTEM ........ 52
FUELPUMP MOUNTING ............... 12 NOSEGEAR ATTACHMENT ............... 52
CARBURETOR ASSY .................. 13 TELEFLEXTUBE & BRACKET ASSY ....... 53
NYLONBUSHING NOTE ............... 14 SEATMOUNT ASSY-CONTROLS ........... 54
TRIKESUB-ASSEMBLIES ............. 14 TORQUETUBE ASSY ................... 55
TRIKEARRANGEMENT ................ 15 MOUNTINGSEATS .................. 56-57
MAINWHEEL ASSY ............... ~ .. 16 THROTTLECABLE ASSY ............. 58-61
NOSEWHEEL ASSY .................. 17 TELEFLEXCABLE ROUTING ............. 62
LANDINGGEAR ASSY ................ 18 SPOILERLINEROUTING ............... 63
AXLEBRAKE ARM ASSY .............. 19 BRAKESYSTEM COMP[ETION ............ 64

•
NOSEWHEEL MOUNTING ......•....... 20 REDUCTION ASSY ..................... 65
RUDDERPEDAL TEMPLATE ............ 21 ORIVESHAFT/BEARING ASSY ......... 66-67
PEDALASSY. ...................... 22 BEARINGLUBRICATION ................ 68
TRI-BAR
ASSY .................. 23-25 MUFFLERASSY ............ •........... 69
ROOTTUBEWIRE ASSY .............. 26 TRIMTABKITADOITION .............. 70
ROOTTUBEASSY ................ 27-28 TAILBOOM "PINNING" ................ 71
COMPRESSION STRUT ASSY ........... 29 WINGWASHOUT ....................... 72
SPARASSY
..................... 30-31 ENGINEBREAK-IN PROCEOURE .......... 73
SAILASSY
........................ 32 WING/STABILIZER INCIDENCE .......... 74
TRIMTAB........................... 75
 ..

• IMPORTANTI

All Eipper aircraft are in a state of constant testing and

modification. These on-going efforts are carried out to
further improve already proven designs, engi_neering, testing
and manufacturing operations. Do not assume, therefore, that
a particular model of an aircraft you build today will be
identical to the one you built yesterday. The possibility
exists that it WILLNOTbe the same.
Stated briefly, pay attention not only to the aircraft's
assembly instructions, but also to the supplemental instruct-
ions supplied with each plane ONANINDIVIDUAL BASIS.

•
ABOUT THIS MANUAL

THISMXIIASSEMBLY
MANUALPROVIDES
BASICASSEMBLY
INSTRUCTIONS
FORBOTH
THE
MXIIANOTHEINTERCEPTOR
VERSIONS.
If you are assembling an MXIIAIRCRAFT,
follow these instructions as written.
If you are construction the INTERCEPTOR, READ
THEINSTRUCTIONS PROVIDED
WITH
THEINTERCEPTOR KIT (packaged separately) FIRST. IT Will BEUPTOYOUTODE-
TERMINE (via the interceptor instructions) WHATPARTORPARTS OFTHISMANUAL
ARESUPERSEDED BYTHEINTERCEPTOR INSTRUCTIONS.
 ,.

II

• INTRODUCTION
Assemblyof ~.our Qukksilver can easily be accomplished in approximately 40 hours.
All ?f the_difficult fab~ication details have been prefinished at the factory. in-
cluding drilling, anodizing, cable swaging, sewing of wing and tail surfaces, etc.
Workcarefully and follow instructions closely. If you have any construction prob-
lems or questions, please feel free to call your dealer or the factory for help.
CONSTRUCTION NOTES
BAS'IC
TOOLS
NEEDED
FORASSEMBLY
1). Twoeach: (ENGLISH) 3/8", 7/16", 8). Scissors, razor knife
1/2", 5/8", 11/16" & (METRIC) 9.5nm, 9). Allen wrenches: l/8 11 & 7/32"
10ml, 11mm,12.7rrm,16nm,& 17.5nm (METRIC} 6mn7 3.2mm
wrenches 10). Sailmaker's hot knife or blade
2). Torque wrench (optional} edge soldering iron
3). Fine flat and 1/2 round or rat-tail 11). Lubricant (3 in 1 oil or equiv.)
files 12). C-Clamp
'4) •. Hacksaw 13). Duct tape or equiv.
5). Electric drill and 1/8", 3/16", 1/4", 14). Pop rivet puller
5/16" (METRIC) 3.2nm, 4.8nm, 6.4mn, 15). Phillips & straight slot screw-
8nm drill bits driver
6). Harrmer 16). Safety wire or "tie wire11
7). Tape measure, marking pencil_
WING NUTSwhencalled out should be backed up with washers (as req.) so that they

• are--as..tight as possible while still allowing the safety ring to pass thru the hole
in the bolt. WING NUTSMUST ALWAYS BESECURED WITHA SAFETY RING. If you do not
have to "totally 11 break downyour aircraft on a regular basis, wing nuts may be re-
placed by locknuts using washers as required.
Bolts that pass thru tubes with no solid internal support should be tightened until
the tube shows just a "slight" distortion, then back off nut slightly. Be oarti-
cularly careful when installing coarse thread grade 5 or 8 bolts.
Loctite all grade 5 or 8 bolts upon final assembly.
CASTLE NUTSare used where bolt and nut assembly is subject to "rotation. 11 Tighten
castle nut accordingly, line up slot(s) in nut with hole in bolt and secure with
safety ring (except where cotter key is spaecified). 00 NOTREPLACE CASTLE NUTS
WITHLOCKNUTS UNLESS SPECIFICALLY ALLOWED IN ASSEMBLY MANUAL. CASTLE NUTSMUST BE
SECURED WITHSAFETY RING(cotter key) ORTHEYWILLVIBRATE LOOSE ANDOFF.
After installing bolts, check that grip length is correct. Using washers as shown,
at least one bolt thread should extend out of nut. One or more washers may be
added to prevent bolt from bottoming out before producing a snug fit. As a gen-
eral rule, a washer under the nut will prevent bolt from turning and digging aluminum.
IMPORTANT! Before assembly check all swagedNicos with Nico Sleeve Gauge provided.
Procedure is diagrammedon toor:- See page III.
Un-twist wires before final attachment. A twisted wire will also be more prone to
jammingor twisting a wire thimble during field assembly of your plane .
• Checkengine owner's manual for proper torque values of engine bolts.
Enjoy building your new Eipper Aircraft. @ppczr aircra~ inc.
~·• urgnt __,,_ al U"7-.,,C Allaaft
 Ill

• NICO SLEEVE GAUGE PROCEDURE

The Nico Sleeve Gauge (20447) is a measuring device which detennines the
size accuracy of sleeves swaging various dimension cables to thimbles,
cable bushings, tangs, etc.
The gauge has precision machined notches for measuring swaged nico sleeves
having 1/8" (3.2 nm), 1/16° {1.6 nm), and 3/32" (2.4 nm) sizes. It should
be used when making a cable inventory upon receipt of your aircraft assembly
kit.
r',;\ TO USE ...
~Insert the swaged portions of the sleeve into the appropriate notch on
the sleeve gauge.
@inability to insert the swaged part of the sleeve indicates improper swage.
REPLACE
THROUGH
YOUR
DEALER.
@1n addition, check the positioning of the cables swagedwithin the sleeve.
Cables are properly swagedwhen they lie directly side-by-side and the
sleeve opening has a syrrmetrical shape. . .

INSERT
NICOINTO
APPROPRIATE
SLOT
.

•
 RUDDERASSEMBLY 1

• NOTE: LOCTITE

1).
All COARSE
THREAD
ONFINALINSTALLATION.
BOLTS

Slide Rudder Cover onto Rudder Frame

as shown at right. The cloth will
have to be bunched up somewhat to
Rudder Frame #.sU•••·
\..

Bendout over~~
car tire 1/2" 1
"\.t; 0 ~ -"',.,..

to makesail -...,
? ~:•·

1
slip onto the frame. taut. 1/2"
(13mm)

2). Slip Rudder Leading Edge Tube into

L.E. pocket on Rudder Cover. Holes
in the tube are at bottom of rudder.
3). Install Rudder Balance Strut (4iiiiiit) as shown.
Attach to L.E. first. LLo~r.:.i•'
,- =>:le'
HEATCUTPOCKET

• SIDE VIEW
PUSHDOWN
SAILTAUT
Mark and dr111
\" dia.
TILL GAPTOBALANCE
STRUT( U l_tl)
't6 3y(,

•
 '-f-03 ---- - 2
RUDDER ASSEMBLY CON'T .

• 4). Install 7/8" Alum. Tube Connector in Rudder Compression Strut,

slip into the pocket and then to L.E. and "pop" aft part of
tube into place.
5). Fasten ends of L.E. as shown.
6). Install Eyebolts into Rudder L.E. as shown.
7). Trim excess Rudder Frame both ends. Allow 1/4"/6mm to
extend beyond Balance Strut and Rudder L.E.

l" Tube Connector #20450 cut hole

Rudder L.E.
#4 0 2 51

-<fit-,1 AN3-13a
111 ALUMINUM
TUBE (10030)7' f,,

•
CONNECTOR(20446)~ I U• +✓ ~ ~
'~ "Q"'Q'. ~ ,,

~ Heat cut holes for

eyebol t in L. E.
S',,
<i'.
c.o.,..

.,..oi
(
• <!"
-1,.,
v~
•
"(2 pl.) : Q' ·9:
)i.-----J
AN43b-14aEYEBOLTS c.o S' 02.s
Rudder Frame (10350). UPPER EYEBOLT """ja <
~o
f
threads into bl i ndnut on
L. E. USETWO WASHERS UNDER
HEAD. LOW-EREYEBOLT: Use TWO
washersunder head, none under nut.
~
11
xl-3/4" Grade' 5 #10400
8). Instill Rudder Control Arm as shown below.
Control Arm #70290
Rudder L.E.--J
#40251 (Rudder cover not shown)

Trim off excess tube -~--AN3-13a #10030

ends and install 7/8"
Tube Caps #20400.
File Insert End of
Cap as necessary. t!Q.TI.:This hole
is factory drilled.
After inserting forward bolt.

•
line up aft arm hole with center
line of tube, mark and drill
3/16" dia.
 3

• ELEVATOR ASSEMBLY.
DRAWING
ELEVATOR
"A11 • Slip ELEVATOR
FRAMES
Install TUBECONNECTOR
then slide ELEVATOR
covers over
(Pockets on bottom).
hardware(4 places) :_
L.E. into sail.
.,
·-- •• ··~ ..
(ELEVATOR ARM hole on right & POPrivets aft.) _,_-_
• ...,._
Install GRADE 5 's and FORKS as shown. TOP VIEW
Do DRAWINGS 8 and "C" as shown.
11 11

NOTE: POPRIVETSIN L.E. FACEAFT. EYEBOLT on

® Stabi 1i-zer T.E. (NEXTPAGE)

1/4"x 1 3/4"
GRADE 5
(10400) ~--l/4"x
3/16"x 3/8" Clevis
Pin(l0440)
1 1/2" Fork
® Heat cut holes as
(10390) 3 places was done in RUDDER
assembly.

TRIMEAR
AS SHOWN

• PG. 1
(2 PL.)

.-::;;;._,_
Elevator compression Strut
(70090) 2 places. "POP"in place.
MEASURE ANODRILL3/1611 DIA. (4.Srmi) 11-3/411 14 ~
in L.E. as shownat right. Mount .
Control Armand "swing" so that rear LEFTSIDEELEVATOR !~ <t_
f hole lines up with center of Elevator
Frame. Hold secure and drill/deburr. ••

,~ AN3-13a(10030) BOTH
ENDS
.
Line up aft hole of arm
with center of Elevator
Frame.
IMPORTANT! DONOTUSEFACTORY
DRILLED HOLE AT10.5" FROM

• vator Control CENTERLINE L. E.

Arm(70070} HEATCUTHOLES
IN SAIL
FOFfNAAO
FORCONTROL
ARM.
SIDEVlEW
 4

• STABILIZER ASSY.
DRAWING"A Take stabilizer frame halves
11
•

and bend "SLIGHTLY" over car tire 1/2"

(12.7 mm) to help make sail taut.
Lay the frame halves on floor flat and
insert into STABILIZER SLEEVE.
Measure, mark and drill 3/16"(4.B mm)
holes for both halves as shown.
Install 3/16" Rfvets (20225).Slip sail •••••••··
•••••••····
onto frame(SEAM of sail on same side
as rivets.) DRAWINGS "B"-"D" assemble
as shown.

Slightly bend frame out 1/2" (12. 7 nm)

over car tire to help make sail taut. 3/16" POPRIVETS
(BOTH SIDES) 4 PLACES.

-----
--~==~-- 0

• -----

.--STABILIZERFRAME
(40265) 2 EACH
TABILIZER
SLEEVE(40266)
~..,.....-4"
1"(25.4 mm)
(101.6 nm)
MEASURE,
ANDDRILL.
MARK

8 Install tube connector at both

ends. Slide STABILIZER
into sail(Nut plate in center
T.E.
faces forward). Use large screw-
driver to leverage STABILIZER
T.E. onto tube connector as r·
il /STABILIZER

~.
~
FRAME

shownbelow. .Q 010 I
AN3-13a(l0030)_,,-,r~~~--._ c· -
-~]_j~ l" ALUMN.
~
TUBECONNECTOR
(20446} BOTH
ENDS.
1
STABILIZER
T.E.(40271)

C: -, .
LEVERAGE AN43B-15a
EYEBOLT(l0370)

r
UP SLID~ONTO
TUBE 3 PLACES.
CONNECTOR.

•
IMPORTANT!
CENTER
EYEBOLT
REQUIRES
TWOWASHERS
UNDER
HEAD.
1/4 x 1 3/4" GRADE
11
5
(10400) BOTH ENOS.
 5
STABILIZER ASSEMBLY CON'T.

• © Heat Cut Both FORWARD

holes on STABILIZER
TAILMOUNT
and AFTmounting
then rest it on the
with seam facing down.

,-w
Install hardware for both aft holes
as shown.
UPPER
TAILWIRE(20501)j -~- _...
20°TANG(20350)
SHACKLE(20320)~
ANDASSEMBLY
STABILIZER
T.E.(40271)

SEAM
FACES
DOWN
l 11x 1/4" NYLON
WASHER(20346)-==::! l"x 1/4" SADDLE(20280)

/Aft hole in TAIL

,----------- .."I"'.-... JI'
MOUNT ang1es down
,.. ••
~:-·· as shown
FORWARD

TAILMOUNT(40170)

• AN4-34a( 10290)
Assemblehardware as shownand STOPat second saddle.
• See procedure below to help insert bolt into TAILMOUNT.
Whenbolt is through TAILMOUNT

G) With head of bolt against

add tang, washer and
nut then repeat procedure for other forward hole.
WASHERREQUIRED
Stabilizer, PULLUPon bolt
STABILIZER
FRAME and insert into first hole
(40265) on Tail Mount.
l"x 1/411 NYLON
WASHER(20346)

l"x 1/4" ----

SADDLES(20280)
2 places. -------
@Now rest bolt
head on
TAILMOUNT woodenbench. .. J:!,-
(40170) VI-
·,: ~
.. ,a. ....
,a
©
90°TANG(20365) Then forward
to insert bo1t .

•
 6
TAIL SKID ASSY .
1) 1/4" Locknut(10510)
• 2) 1/4" Washers(l0560)
3) Rudder hinge fork(l0390)
4) AN4-26(10241)
5) 1/4" Washers(10560)
6) l"x 1/8" Saddles(20270)
7) 1/4" Wingnut(l0520)
8) Safety Ring{20310)
Repeat steps 1-8 for lower
half of tail skid assembly.
Attach Rudder to Tail Skid
with Clevis Pins as shown.

RUDDER ►
6
~TAIL SKID
(41150)

WrapDUCT TAPE
around 3 times to
prevent ELEVATOR
contact .

• TAIL MOUNT40110)
RUDDER BRACE
(40181)f
7

TUBECAPNOTE:
FILE 7/8 TU.BE
CAP(20400) ASNECESSARY
ANDINSERT. SECijREWITH1/811 POPRIVET
DRILLING HOLE90 TOHINGE FORKHOLE. •

•
• TAIL SKID ASSEMBLY • • •

1 x 1/8" SADDLE(20270)
2 needed.
7/8 SADDLE(20265)
11
TAILSKID
g
2 needed REAR _VIEW
(WHITE)
TAILBRACE\
2 places 1 WASHER
ONLY
(41440)
AN4-36(10293)

t1=======:::mm:mmlmzmm--(8
JE--<t 0
~
,-8 jjjjt•-,
Ii iii! 00 Oil iiiOiiii

t_AN4-40(10298)
WINGNUT
( 105;

0
)-
SAF.ETY
RING
(20310)

1 WASHER
EACH.SIDE~

LOWER TAILBOOM _/
2 places (41224)
J MAIN
AXLE
1 x l/8 11 SAODLE(20270)

I
4 needed.
TAILBOOM
BENDS
AS
SOOWN

TOP VIEW

BOTHTAILBRACE M
ANOBOOMBEND
ASSHOWN --..i
 ___________________
TAIL GROUP ASSY. a

•
AFTER
COMPLETION
OFTAIL
GROUP
SUB-ASSY.,
SETIT
ASIDE. YOU
CANREMOVETHE
LOWER
TAILBOOMSTOSAVE
SPACE.

Tail Boom
(40225)

l"x 1/8" Saddle(20270)

7r 1-75 Channel(20080)
AN4-16a(10140)

7/8 11 TUBE
CAPSBOTH
ENOS(20400)
SECURE
WITH1/8" POPRIVET
DRILLING
90° to BOLT
HOLE HOLE
.

• t • AN4-16a(10140)
ADD2 WASHERSINSIDECHANNEL
TOTAKE UPEXCESS (7/8 TUBE,l" CHANNEL)
CLEARANCE .
Channeland PROPARCWARNING
label
, face outward

! SEEDETAILBELOW
~ L Tail Boom(40225)
Rudder Brace{40181)____,..

1/4 11 Locknut(l0510)

Tail Brace{41440)

B
FRONT VIEW
STABILIZER
_/
AN4-14a {10100)

•
LEFTSIDE Both sides.
\_ 90°TANG 111 TUBECAP(20410)
SECURE ASDESCRIBED
◄ RUDDER
BRACE ABOVE.
 9
EXHAUST HEADER ASSY .
• INSTALL
EXHAUSTHEADER
ANDDRIVE
SHAFT
WHEN
HOLE
ASSHOWNBELOW.
INSTALLING
SPACED
DRIVE
SHAFT,
3/4" FROM
ENDGOES
® Measureand drill 3/16"(5 nm) hole in
engine casing as shownfor FUELLINE
STAND OFFwhichwill be installed
on the.ENGINE RE-INSTALLATIONpage.
INTOENGINE
COUPLER.-

NOTE:YOUAREGOINGTOSUB-ASSEMBLE
THEENGINE/MOUNTS
ONTHEROOTTUBE,ALIGN
THESHAFT,
ANDTHENREMOVE
ENTIRE
UNITFORREASSEMBLY
LATER.

DRIVESHAFT REMOVE
SHIPPING
STUDS
FROMENGINE
(60058)
AN5-20a
(10323)
TORQUETO240 in/lbs.
(27.1 N-m)

• \

)
I

I
I

8n1nAllen Head E~HAUSTHEADER

Bolts (61045)
4 needed.
HEADERWASHERS Exhaust gaskets

• (4 PLACES) #008318402 needed.

 10

• EN·GINEMOUNT ASSY .
SEE NEXT PAGEFOR NOMENCLATURE

SHIM
ENGINE
ANGLES
FORINITIALASSEMBLY

ROOTTUBE\

•
IMPORTANT!
SEEDETAIL
A

TOWARD
BOLT
HEAD

~ Q'SIDEVIEW

SPLITRING~ •
"WAVE"LOCK- DETAIL
A - IMPORTANT!
WASHER NOTICE
THAT THESE
LOCK-
• WASHERS
ARENOTFLAT.

• THESE
AREPROVIDED
THEENGINE
IN
BOX.
HIGHPOINTS
4 WASHERS TOWARD
BOLT
MUST
BE
HEAD.
 11

•
ENGINEMOlM NOMENCLATURE.

Follow the sequence and notes carefully 10) Rubbergronmet {30380)4·per

as shown. DONOTfinal tighten any assembly. Note direction of nipples._
bolts(unless noted) until later steps 11) 5/16" Washer(l0570) 5/16" Locknut
for drive shaft alignment. (10540)
12) AN5-30a(l0328)2 needed.
1) lOmnx 30mncoarse thread bolt. 13) 1/4" Washer(l0560)
(10492) 4 needed. 14) Right engine mount angle{60092)
2) SPLITRING"WAVE" WASHER. 15) 5/16" Washer(l0570) 5/16" Locknut
(4 req.) (10540)
3) Lowerengine mount.(60082) 2 needed. NOW REFERTOSHAFT ALIGNMENTBELOW.
4) ANS-10a{10305) 4 needed.
5) Upper engine mounts.(60071)
2 needed.
6) Left engine mount angle(60091)
Also Right engine,unt angle
{60092)callout # 14 in illustration.
7) 5/16" Washer(l057 5/16" Locknut
(10540)
8) ANS-24a(l0322)4 needed.
9) Fender washer (10600) 2 per assembly.

SHAFT ALIGNMENT
G) SHIMONEOFTHEENGINE
ANGLE
MOUNTS
WITHSIX SHEETS
OFORDINARY
WRITING
PAPER

• ASSHOWN
ONPREVIOUS
@NOWTIGHTEN
THETWO
@WITHALLTHEOTHER
ASSHO\ffl
BELOW.
PAGE
.
ANS-30aBOLTS
BOLTS
THAT
ATTACH
STILLLOOSE,
ENGINE
ANGLE
LINEUPDRIVE
MOUNTS
SHAFT
TOROOT
WITH
TUBE.
PROPSHAFT

@Now THAT
SHAFTSAREALIGNED,
TIGHTEN
ALLREMAINING soTHECOMPLETE
BOLTS
ASSEMBLY
IS SECURE.
@REMOVEENGINE
ASSEMBLY
FROMROOT
TUBEBYTAKINGOFFTHETWOANS-30aBOLTS
ANO
SETTING
ENGINE
ASSEMBLY
OFFTOTHESIDEUNTILRE-INSTALLATION
IN LATERSTEP.

PROPSHAFT
ON
ROOTTUBE

DRIVE
SHAFTON
ONENGINE

-••► ◄-----•

•
LINESHAFTS
UPTHENTIGHTEN
ALLREMAINING
BOLTS

BACK VIEW
 12

•
FUEL PUMP MOUNTING-
Measure,mark and drill two 1/4"{6.4 mn) holes on LEFTENGINE
ANGLE
MOUNT
as shown.
MountFUELPUMP
to ENGINE
ANGLE as described below.
MOUNT

@ TOPVEW
@
I
<FORWARD I

I◄ 3-3/8 11
85.7 nm
-0-I

..I- 2-13/16
71.4 nm
11

.,
-(±)-1
I

3/8"
9.5 mn
LEFTENGINE
MOUNT
ANGLE
(60091)

• LEFTENGINE
ANGLE
MOUNT(60091)

I
FUELPUMP {60045)
Note direction of
fue1 fl ow arrows
on bottom side.
! FUELFILTER(30210)
Note direction of
fuel flow arrow.
SMALL HOSE CLAMP1 ELLINEFRO
Use for all fuel
line connections.
(30230) f+-9-1/4"-.-.j
266.7 nm 235 nun. j
.,_ FUELLINETO THISENDOF FUELLINEGOES
CARBURETOR TOON/OFF VALVE
ONFUELTANK
AFTERIT HASBEENASSEMBLED

•
TOROOT TUBE
.
Fuel line goes to fitting
on bottom of p~.
See reference® on next
page for engine hook up.
 13

•
CARBURETOR ASSY .
NOTE:THISPAGE
CANBEDONE
POST-ENGINE
RE-INSTALLATION,
IF YOU
PREFER.
MountCARBURETOR as shownbelow. Drill out STARTER
CASING
HOLES
as shownfor
routing of electrical lines shownlater.

Drill 3/16" (4.8 11111)

hole for tie wrap
to secure electrical
lines. --
_.- PULSE
FITTING
SEEREFERENCE®
STARTER-- PREVIOUS
PAGE
CASING

• ...
,,,
/4'
,,
:
:-I ~7""-1:sa.-. HOSECLAMPS
(2 NEEDED)
\
..,,______
CARS MOUNT
\
\
- \ I
BLOCK#
00867481
I

''
... ¥
-- '' .....
THROTTLE
ASSEMBLY
.
CABLE
TOBEINSTALLED
IN A LATERSTEP
IMPORTANT
Tighten clamps so there is a
gap as shown.
1/4"(6.4 11111)
1/4"(6.4 11111)~ 14--

• DONOTINSTALL
CABLE
HASBEEN
LATER
STEP
UNTILTHROTTLE
ADJUSTEDIN
 NYLON BUSHING NOTE 14

•
Reaminner diameter
if necessary.

The NYLON BUSHINGS may need sane reaming out to rotate freely
on the PEDALS, THROTTLE and STICKATTACH TUBE.
After the bushings have been put in there respective places,
see if rotation is easy. If this is not the case then REAM out
inner diameter with rat tail file or 3/4"dia_. wooddowel with
sand p~per wrappedaround it until bushings movefreely.

Whenmounting pedals onto pedal mounttube,

DONOTbolt into place until NYLON BUSHINGS
rotate freely on tube.

•-----------
TRIKE SUB-ASSEMBLIES
IN THEFOLLOWINGSECTION
YOUWILL
BESUB-ASSEMBLING
COMPONENTS
FORTHE
TRIKEASSY. IT NILLNOTBECOMPLETELY
ASSEMBLED
ATTHISTIME.
STEPS:
1. Refer to the "Trike Arrangement"Drawingfor an overa 11 view.
2. Sub-assemblemain wheels/tires and nose wheel/tire. NOTE
THEDIFFERENCE.
3. Sub-assemblethe main axle adding all saddles, channels, wires,
tangs, axle stubs, etc. as called out.
4. Sub-assemblenose forks/nose wheel. Addtension struts and com-
pleted rudder pedal assy.
5. Sub-assenmletri-bar adding sheath bracket, pulleys and nose wires.
6. Attach channels, hardware, and wires to root tube as shown.
DONOTASSEMBLE
TRIKEATTHISTIME. INSTEAD,
SETSUB-ASSEMBLIES
ASIDE
ANDCONTINUE
ONWITHWINGCONSTRUCTION
.

•
 • TRIANGLE
BAR
CHANNEL
(20100)
Attached to
TUBE
ROOT
SAFETY
RING(203•
WWGNUT(10520)

,,
,,,-
,, ,,,,
,,,,
.J.._
~
--~AN5-46 (10345) •
-I
-m
::IJ
AN4-34a
(1029~)
$ )>
"
TUBE
(ROOT NOTSHOWN
FORCLARITY), m ::IJ
"'1 ::IJ
i ~ )>
i : I m Z
I.~
l

! ! . iI. ~ Ci)
i ,: ! ' . !' •
A----~•!· II mm
. c:,__--," :;: I I. 0 3:
FORW : I: I!;
:
'
. :

:
...
j

!
' •
I:''
I iI iI ;; .;
! :
i I II iI i :
• I ! I: I:
I
I • I ! .
' . ~
-< z
m
..
I •
' f..
' :
' I I ' ' ' . I : • I
I
•
./ LANO
It«i GEAR
- -t
EDGENOSE : : • ~
FILE BOTTOM ,- DOWNTUBE (40291)
STRUT
TOAVOID
CONTACT: : .,,
~
WITH
BOLTHEAD
(BOTH
STRUTS)
I (40310)
NOSESTRUT~
(40360) · .

PEDAL MOUNT---.....XJ
TUBE (80100)
( PEDALSNOT·
SHOWN)

~·'O ~
_/ ' TENSIONSTRUT
NOSEAXLE/ (41301)
AXLESHAFT ...&.
(20030) en
 TIRE 16
MAIN WHEEL ASSEMBLY UN-Notched Hub Notched Hub

•
(20461) (20460)
Take the two wheel halves, notched goes inside goes outside

l
(20460) and UN-notched(20461)and
assemble as shownin drawing on
right. (Makesure air valve stem
on inner tube comesout of
notch on notched hub.)
NOTE:See next page for nose wheel.
< INBOARD

. Start one of the three NEW AN-5~32a (10330}bolts through the outside wheel half
(valve stem side) ~nd add alum. spacer then ·the DRUM TRI-SPACER (91204) and the BRAKE
ORUM (91202) as shown (again, pay attention to proper "wheel halves"). Put on the 5/16"
LOCKNUT (10540) and WASHER "finger tight". ADOthe two remaining BOLTS/WASHERS/LOCKNUT
as you did the first and as ·shownin the drawing.- NowTIGHTEN all the nuts accordingly.
Inflate tires 25-30 p.s.i. but do not mount to axle yet.

AN5-32a(10330)~
5/S"xl/2 A1umn.
11

•
I of 3 per assm. \
Spac·ers (91208)
1 of 3 per assm.

OrumTri-Spacer
(91204)
"STANO-OFFS"toward
wheel half

Brake Orum
(91202)

5/16" Locknut .
( 10540) 1 of
3 p\sm.

REMEMBER! UN-NOTCHED
wheel hub goes inside.

NOTE: PRIORTO INSTALLATION,

RUNEACH
LOCKNUTONTOEACH BOLTANDOFFAGAINTO
5/16" washers EASEASSY. KEEPHUB(HEAD SIDE)FROM
BEINGSTRIPPED.
(10570)
 ••

NOSE WHEEL ASSEMBLY

• •
Assemble hubs to ttre with the hardware shown.

< INBOARD I
TIRE and TUBE(20390)

Ul~-Notched
Hub Notched Hub
(20461) (20460)

--fHHr s
5/16"xl ·l/2"x24
Locknut (10395)
( 1 of three) ( 1 of three )
(10396)

Notch for air valve

.......
 LANDING GEAR ASSEMBLY
Wingnutand safety ring l 11xl/8 11 SADDLE
{20270)
(2) 18
.10520 2Q310

•
DRlLLTO5/1611 DIA.

~AN5-46(10345)
-~
~DO NOTATTACH LANDINGGEAR
DOWNTUBESORROOT TUBE
A! THISTIME.
DETAILA - AXLESTRUT
(80090)

LANDING
(40291)
GEAR
DOWNTUBES
TO
DMAIN
GEAR
ti-Torque plates FILE"U" SHAPE
IN TOPSIDE
7) 2 per side
TUBEENDONLYTOALLOW
AN4-22a CLEARANCE7NiJT
/BOLT)~-JHEN
(1019 FOLDED.

•5-1-125 Landing Gear Side Wires.

channel ._20°TANG(20350) '(20615) (to T.E. wing)
(20060) ROOT
TUBEWIRES.
2 reqd. ATTACH
HERE.
IN
LATER
STEP 1-75 CHANNELS(2008
2 per side as shown.
..-AXLE
(40310)

AN4-23a NOTE:AXLE STRUTS

ANO
(10210) 'i'Em°ION
STRUTS
AREATTACHED
(IN BRAKE LATER-USETHISFORREFERENCE
KIT)
Wingnutand safety ring
10520 20310

AXLESTRUT~
(80090) .
SEEDETAIL
A

•
 19

•
AXLE BRAKE ARM ASSM.
'NOTE: THESTEPSBELOW
TAKE
PLACE
ONLY
AFTER
DOWNTUBES
AREBOLTED
INTOPLACE.

Main Axle
(40310)
a. Push the AXLEBRAKE ARM(91206) (1 of 2) Axle Shaft
between the two ANTI-TORQUEPLATES until the (20030)
TOPof its "cutout radius" is flush with
the MAIN AXLE. ~
0
b. Now"MATCH UP" the four holes in the AXLE
BRAKE ARM with the cooresponding holes in the
two ANTI-TORQUE PLATES as shown. WhenAll FRONT VIEW Oril l 3/16"
• /4.8rrm hole
HOLES LINEUP and 'the TOPof the AXLE BRAKE
ARM'S"cutout radius" is flush with the main . .. - -
axle, the BRAKE ARM/TORQUE PLATES·areproper-· --
Lana. lie ar-own.
ly aligned for drilling. Add a "CH CLAMPto SIDE VIEW UP Tube (40291)
help hold the parts in place.
AXLEBRAKE
3/16" ARM(91206)
c. DRILLING.Use3/16" /4.Srrm DRILLBIT.
DOUBLE CHECK ALIGNMENT and then drill ONEof
the four holes through the MAINAXLE(one
{!~~;~))
Anti-Torque
Plates (2)
side of tube only) using the AXLEARM/Pt:A-TE"'--- .....
.2.--· [91Z071 __ _
HOLES as a "guide." Whenfinished drilling
the 1st hole, put in a 3/16"BOLT(any) to
act as an ''alignment pin". REPEAT DRILLING
PROCEDURE AS DESCRIBED ONREMAINING HOLES.
d. Nowdrill (from either side) through each
"set" of holes to duplicate the bolt path and \
add the AN3-22aBOLT/WASHERS/NUT
~•-
as shownto 3/16" Locknut
CAN3-22a (10054)
(2 per side)
each of the two bolt holes. (10500) Main Axle (IN BRAKE KIT)
Repeat above steps for other side. (40310)

•
 NOSE WHEEL MOU~-'. lNG
------•-------
--..
NOSE STRUT
AN4-15a(l0120)
Attach TENSIONSTRUT BRACKETS
to ILNSION
STRUTS
before
assemblingother hardware. 10030 ( ref)

NOSE
AXLE
TENSION STRUT/~ FITTING
20020
AN3-13a
10030
(2 Places)
SAFETY
RING(20310)~
WING
NUT(l0520)-. '
+
NOSE STRUT
(40360) AN3-13a(10030)--...._,
2 per bracket. ~
'
NOSE
AXLE
SPACER- 20040
( 2 places)

TENSION STRUT
(413017

+ NOSE
AXLE
20010
,~ NOSE
WHEEL
ASSY.

\
\_ '
~ USEWASHER
FORSPACER
TEHSIONSTRUT
ONBOTH
SIDES.
BRACKET
(41301) 1 each strut.
~
TOPVEW

' NOTE:ONEENDOFTHETENSION
STRUT IS
"'---- BENT,THISENDGOESAFTAND THE
AN4-16(10130) BENDSPOINTSTRAIGHT ANO
BACK
Use AN4-15aon other side. NOTTOTHEOUTSIDE.--~---'
------------------------~:: ___________________ .. I\)
0
 RUDDERPEDAL TEMPLATE 21

• PEDAL
TEMPLATE
OVER
SHOWN
LEFT.FORRIGHT
TEMPLATE
IS PILOT'S
PEDAL
TURN
ANDREPEAT
INSTRUCTIONS
BELOW. {
,,,,,-· ¥
/ FOOT PEDAL
. (70230)
DRILL BEFORE
INSTALLING
~-90°TANG
·~ (20365)

ROUND
OUTBACK EDGEOF
PEDALS
WITHA FILESO
TANG
WILLFIT FLUSHAS
SHOWN
BELOW
.

• ---·- ---·---------·--·-- ·-· -

AFTER FILINGPEDALS
FORTANGS,
UPAGAINST
VERTICAL
GIVEN
PLACE
PEDAL
TANGS
WITH
MEASUREMENTS
ANODRILL(2)
3/1611 (4.8 ITl11)HOLES.

l~~o -90°TANG
...... ~ (20365)

•
l

•
FRONT
VIEW(STANDING
PEDA~ ASSY.
____
ATNOSE
WHEEL
_
LOlfINGAFT)
PEDALSRIGHTSIDE
•
PEDA~ LEFTSIDE (70230) (4)
PEDALS
RIGHT
SIDEVIEW
SIDE
~
PEDALS
•
LEFTSIDE
\ CI
~

FOOT
PEDAL
TUBE 1RILL
3/16 (4.8 nm)
11
AN3-17a
SPACER HOLES4 PLACES THEN (10050)
(80180) INSERTAN3-17aBOLTS.'·' 4 PLACES.
.~
(2 EA)

10-15° OFF
NYLONBUSHING VERTICAL
8 EACH· FROHNOSE
l"xl/4 SADDLE
11
(70250) SPACEHERE
WITH
1/4" AS STRUT
4 REQ'D(20280) NECESSARY
TOGETPROPER AN4-14a(10100)
STOPANGLE. FOOT
PEDAL
STOP
(2 EACH)
NOTE: Makesure NYLON BUSHINGS rotate freely
before bolting pedals 1_ntoplace. BOTH DRAWINGS ARE PILOTS LEFT PEDAL (TOP VIEW)
1 Insert NYLON BUSHINGS(70250) on inside UPPER
HOLE
SPOILER
ASSEMBLY LOWERHOLEBRAKEASSEMBLY
of pedals.(8 each)
2 Slide pedals onto PEDAL
shownabove. NOTE:
SPACERS
MOUNT
TUBE
as
Whileslid;ng pilot's
pedals on, slip on FOOT PEDAL TUBE
as shown.Nowinsert AN4-14a
AN3-5a(l0010)
I I •
iWI
r
"1
90°TANG
(20365)

bolts for pilot's pedals. AN3-7a(10020)~o;:_:::m

__ -
3 Drill holes for pedals on left and 90°TANG/ SHACKLE
ASSEMBLY
insert AN3-17abolts as shown. (20365) FORBRAKE
CABLE
(REFERENCE
ONLY)
4 Assemblehardwarefor pilot's LEFT PULLEY90°CLEVIS
PEDALas shownat right, then repeat (20232)
process for pilot's RIGHT
PEDAL. BRAKE
CABLE ►I

"-J
I\)
I\)
 •

TRI-BAR ASSEMBLY 23
• Put TRI-BAR
together by drawingsequence.
@ Install Spoiler pulleys and Tri-Bar
Sheath Bracket (See note)..

TRI-BAR SHEATH BRACKET{91226)

See Brake Kit AssemblyInstructions
REAM 2 OUTSIDE HOLES
ASDESCRIBED.
and then attach nowprior to Tri-Bar
Assembly.

•
AN3-7a(l0020)
2 places

WASHER
UNOES
NUTONLY
j Insert PULLEYBUSHING(20240)
betweenholes. 2 places.

PULLEY(20230)
2 places

NOTE:·ooNOTFINALTIGHTEHPULLEYS
UNTIL ROUTING
ENTIRE OFLINE
HASBEENCOMPLETED
TODETER-

• MINEPROPER
LINERUNS
ATTHAT
ANGLEFOREACH
ONNYLONPULLEY
(SO
ONLY).
TIMEFINALTIGHTEN.
 24

• TRI-BAR ASSEMBLYCONTINUED.
Assemblehardwareas shownbelow for right half of TRI-BAR
then repeat assemblyfor. left side.
CROSSTUBE

~-TRI-BAR DOWNTUBE
(41230)
TRI-BAR NOSE WIRE---.,
(21600) Both sides

AXLE
STRUT
ATTACHES
HEREWITH"T" -HANDLE
PIN.
LOWER F YINGWIRES. lx l/8 SADDLE
11

,.,,.--- L.E. INBOARD21540 (20270)

__.---L.E. OUTBOARD(21530

• T.E. OUTBOARD(21520
T.E. INBOARD(21510)

AN4-17(10160) TRI-BARCROSSTUBE
i/4"-WASH"ER
( 10560) (70555)
2 needed.
1/4" WINGNUT(l0520)
SAFETYRING(20310)

• NOTE:LOWER
FLYING
WIRES
ATTACH
FORREF.ONLY.ATTACHED
TOTRI-BAR
LATER
.
 25

• TRI-BAR ASSEMBLYCONTINUED.
To ease installation, lightly lubricate the inside of UPPER
whereTRI-BAR
into UPPER
DOWNTUBES
TRI-BARONLY
again insert into UPPER
1/4"~6 nm). Bendother TRI-BAR
ASSEM
TRI-BAR
will be inserted. Insert one of TRI-BAR
DOWNTUBE
LYonll l/4"a6 nm). Use a RUBBER
ASSEMBLY
OOWNTUBES
out and
MALLET
(Not a metal hanmer)to tap UPPER TR-BARownonto DOWNTUBES.
Alternate t s from side to side and onl ta in 1/411 6 nm increments.
~ou tap one s1 e too ar t w 1n. 1ne up o es an insert
har wareas shownbelowfor both sides.
#,.,,,.,,
c., .., ALTERNATE
TAPS1/411 (6 mm)
r,. ,
,,
I I ..,

,,,,
,',
, I
I I

UPPER
TRI-BAR
ASSEMBLY
,.,___ TRI-BAR
-----1~1

--
LUBRICATE
INSIDEOF DOWNTUBES
UPPER
ASSEMBLY (41230}

•
UPPER
TRI-BAR
ASSEMBLY
__ .,./
(80170)

-~NUT ONREAR
SIDE
AN4-15a
001292
Both sides

..,.___ TRI-BAR DOWNTUBE

(41230) 2 places

•
 26

• ROOTTUBEWIREASSY.
Removenuts from AN4-30abolts, take one washer off bottomand re-assemble
75o TANGwith_just one washer on bottom.
IMPORTANT!Workon just one washer at a time so the PULLEYUNITwill stay in ·line.

75°TANG(20355)

GRADE
5 BOLT
NOTSHOWN·
FORCLARITY
.

• WARNING!
DONOTOVERTORQUE.
TO7 FT. LBS.
TORQUE ROOT
TUBE
WIRE(20604}

SHACKLE
(20320}
CLEVIS
PIN (10440)
SAFETY
RING(20310)

NOTE:THESE WIRES
ALLOWYOUTOREMOVETHEWINGSANOLEAVE
THELANDINGGEARIN THE"TRIKE"
FORM.ALSO,TOAID
IN INSTALLING
THEROOTTUBEWIRES,DISCONNECT
THE
LOWER NOSE
WIRESANDRE-INSTALL
AFTERINSTALLING
THE
ROOT TUBEWIRES.

OPPOSITE
ENOATTACHESTOTANG PREVIOUSLY
INSTALLED
__ __,
ONMAINAXLE(ANTI-TORQUEPLATES).USESAHE
SHACKLE,
CLEVIS,ANDRINGARRANGEMENT.

•
NOTE:PUSH/PULL
SAFETY (20627)ALSO
ATTACHES
HERE
ViASAMESHACKLE{THIMBLEEND). ATTACH
AFTERPUSH/
PULLINSTALLATION.
 27

• ROOT TUBE ASSY .

Assemblehardwareas shownfor DRAWINGS
IMPORTANT
WITHTHE
MAKES
AFTERTHEAIRCRAFT
KINGPOSTTIGHT,BEND
A STRAIGHT
HASBEEN
TANG
"A" and "B".
BASICALLY
ASNECESSARY
LINETOTHEKINGPOSTATTACH
ASSEMBLED
SOWIRE
POINT(OPPO-
SITEENDOFWIRE).DOSOBYPLACING A SMALL
PIECEOFWOOD OFTHE3/16" ATTACH BOLT HEAD
ANDTAPPING WITH~ER ASREQ ..
THISALSO APPLIESTOKINGPOST ROOTTUBE
ATTACHTANG OFNOSE WIRE. ASSY.
THEPROPENDOFTHEROOT
TUBEASSEMBLY CONSISTING
OF THEPROPSHAFT,
HOUSINGANDCHANNELS
{20060) IS ASSEMBLED
AND
ALIGNEDATTHEFACTORY.

• rtN3-6a
~10015)

'
14-- KINGPOSTNOSE
{20595)
WIRE

S-175
CHANNEL ROOT
TUBE
{20050) ASSEMBLY
(2 PL.)

. TRI-BARNOSE WIRE
ASSY(21600)
REF.ONLY-
DONOTATTACH LOWER
TRI-BARWIRESAT 10560_,_=-

• THISTIME. ATTACH
REMAINING
FINGER
HARDWARE
TIGHT. 10510~
DETAILS
CONTINUED
ONNEXT
PAGE
 28

•
ROOT TUBE ASSY. CON,- .

KINGPOST
1-75 CHANNEL
(20070)

TUBE UP
ROOT
ASSEMBLY
AN5-30a
{10328)
FWD
TRI-BAR CHANNEL
(20100)

• FINGER
TIGHTEN
FORLATER
ONLY
ASASSEMBLY
CONSTRUCTION.
MAYBETEMPORARILY
REMOVED

IN THENEXT
SECTION
YOUWILLBEBUILDING
THEWINGS.FOLLOW
THESTEPSCAREFULLY,
ESPECIALLY
WHENFITTING
ANDCUTTING
THEWING
COVERS
.

•
 COMPRESSIONSTRUT ASSY. 29' .

•
... -
_.........

l" TUBECONNECTOR
SADDLE(20450)
.. COMPRESSION
STRUT
• ''@.
REF.ONLY '@
SEOLA_~ .. THREADED ALUM.INSERT
-·/. (20380) (12 PLACES)
,- /

Assembleall compressionstruts as shownabove.

NOTE:There are two types of compressionstruts:
s i.x SLEEVED
(40284) and two UN-SLEEVED
(40280)

•
On two of the SLEEVED COMPRESSION
STRUTS add
PULLEY ASSEMBLY
as shownbelow.

BUSHING /TRAILING EDGE

SPAR
(20240) REF.ONLY ~
,-........ --~
d ,'--.... ~ ..
~ ,,, .....
......._,,#"\_
REF.ONLY
~'@_ "---,, USED
LATER

PULLEY
(20230)
', )
'--...__,

SLEEVED
STRUT(40284)

•
 SPAR ASSY. LEADING TRAl&.lNG 30
ll>GI SPAa EDGE SPAR

Io;; INBOARD <Ol

•
·,op RIVff

FACTORY INSTA&.&.ID POP RIVETS ON

THI &.IADlNG IDOi AND TRAD.ING
/ B "' SPAJl SHOULD FACI INBOARD ON WING.

',~',
'
I

,,_R_OO_T-TU_B_S_A_S_H_NII
__LY---, ~ ~i.J~:I
Approxl.-ata&y 30 lnc:be•

hilb. "
,,

',

FWD MOUNT IIOOT TUBS ASUNa&. y.

UPSIDE DOWN ON SUITABU
SUPPOaT AMD ATTACH UADING
AND TllAILJNC I.DGS SPAiia AS
UP SHOWN

NOTE:REMOVE
TRI-BAR
CHANNEL
IF USING
SAW
HORSE,
SOIT LIESFLAT
•

•
ROOT TUBI ASSIMBL Y
I.IADINC / INVIRT!D
IDGS SPAR
(80050) SAFETY
RING(20310)
Both sfo7

CASTLE~
10521) Both sides
ROQ1...'tUII'
ronwvd, ■nd
Ll!ADlNG
:.../41t-----AN4-25(10230) IDOi SPAil
(80050)

•
Both sides .
DETA1U CONTJN\mD NUT PAGE
 31
8)-------------------------
• -
Prop end of IIODt Tube A....tll1
IDYerted

•
 SAIL ASSY.
,ULL
ql]_TWAIID 32

• 2 CENTER RIBS
(80190)
NOTE:USEBARSOAP
ONTOPENDS OFRIBS
TOKEEPTHEM FROt1
TBOAllD 0aONNST
-=Ii... •
. STICKING
IN SAIL
IIO
(FORREMOVAL)

• DOWN

_______ PA_RA~n •v ,_,_, ____ N_o_T_PAM~n spar

I
OUTBOARD
o---------*--------i CORUCT lNBOAAD
1-=--------,+--fi----------ze:e I
INCOIUUICT

(D WITH ROOT TUBll AND SPAR ASSIDCIILYDIVDTD> AND SUPPOaTD Aa SHOWN. SLID& SAD.S OVER SPARS
AND ATTACH WLCRO STRIP.
CD
INIIRT THI 2 CINTD RIIS IN ll1B POCIITI, (0NI BIi DI IACB IAD.).
(D PU~ IN•OAJlD SAIL INDS (4 PLACU) UP PLUSH lfIT1l CIIAJCNSL nTTlNOS ON ROOT TUBE. (2 CHANNIL
FlTTlNOS ON LIADtNO &DOil SPARS AND 2 CRANNn PITTINGS ON TUILJNO llDGll SPARS.
© GJIOMMIET
USING TU FACTORY INITALUD SAD. ORONNSTa Aa LOCATORS. DRD.L POua 3/ll• Ct.I -1 HOLU THRU
HOLU INTO THIE tNBOilD INDS ·op nn L&ADING AND TliU.JMO llDGll SPAJIS. POP IUVllT SAILS
IN PLAca. Be correct-only one hole in this area can be drilled.
© WtTH T1lll POUJl INBOAJU>JUVllTS HCUllllD (2 llACB SAIL) Puu. SAD. INDS OOTWAJlD APPROXINATILY
S0-40 LBS (13.n-ll.l 1t1) AND MAU OUTBOAllD GROIOGT LOCATtoN. (USS Pmtcn. OR SHARP POINTED
SCRtBD THRU GROMMllTKOUS) SLma BACJC SAlLS AND DRILL 3111• (4.1 -> NOUS IN SPARS WHEAi

•
lNDICATllD: NOfl: MAU SUU TD• lNBOAIU) AND "OUflOAIU) GROaaaT HOLH Al.lGN PARALLEL ON
SPAJlS (SD IBXmrANJ POP IUVrT SAU.I INTO !'LACS •
 STRUT ASSY. 33

• STUDY THIS OINUAL WIMGAIUlAIIODIDIT,

UNDGID TU WING l$ UPSma DOWN.
TBD STUT ASUNJILY 1flTH DETAIL "A".

DIAGONAL STIUJT
40244
(l SACK WING)
coaa.as110N STllUT
"'BOU• IN WUIG COVDJNG
., (I PI.ACU SACK WING)
,,' ,,
, ~,-,,~,

,
.,,,, ,
..;;:,' lllll POCKET
(7 UCH WING)
,•,,
,..,:;,,
,,,
RIB• (80190)
(I Pl.ACES EACH
B WING)
( Z INBD. RIBS
QR! PHVIOUSLY
CONPUSSJON INSTAI.LIDl
STllUT "BOLT HOU" _/
IN WINO COVDING,
II PLACSS IACH WING)

Sleeved
CONPHSIJON
STJIUT•40214
(2 UCH WING)

• ,,,,~,,
,, ,,
,.,.,,,,
,,:,/ D
,,.,:,,
, ,,, /'
1;,"
,, ,,, .

~OUTaOAJID
FOJIWAJID

.,,,

TD' ITJIUT
41411
11 IACH WING)

REF.DRAWING--START
ASSEMBLY
ONNEXT
PAGE
WITH(A).

• DETAILS CONTJNIJZD NSXT PAGa

 34

•
USS Tld TDPLAff PATTON ON TD IQXT PAGI, DITAU. (A-CONTDIUU>), TO 1.0CATB THZ HOUS IN THI WING
COVIB FOIi THI DIAGONAL AND COIIPUSIION ITJlUTI.
© I.OCAn THI
AS SHOWN.
0
HIDDIM~ FACTORY Pl'IDBll.ta) aOLT HOL&S IN SPAJI aY RUNNING FINGDl OWll SPAJI

(D AHAlJt TRI
,acn..
l;Klfflll or nm "llDDU"
SD VIIV "A•A" 11:LOV.
IOLT uou. ANO SCRtll! A LINE AT RICKT ANCU: TO SPAJl WITH

"Kldclen • Bait Hole

wider wtncconr,
laceta. but do noc
c:ut GIit et tJlia u.e.

VIEW A-A

+f
SPAii

-E
•
WRONG

(D CDITIJl THI LOCATD HOLi IN THI TINPLATI ona THI SCJUam LINI. MOVI THI TD4Pt.ATI FOIIWAIID Oft
AFT AS lNDICATID alLOW AND NAU LOCATION ON THI WING COVD THIIU HOLi IN THI TIMPLATt WITH
A PINCIL. NOTJCI THAT THI USI OP THI TIMPLAff JS DJPFUDT ON THI LaADlNG IDCI SPAR AND THI
TJIAILlNG IDG& SPAR. HPIA'f""XT I PLACU ON IACH WlNO.
..
LOCATD IIOU IN TDaLATI

ALIGN IDOi OP II.Ml 1ftT1I 1J1t1. ON

TIMPLATI roa
IDOi OP WINO,
.mm ON Tlllt"lNG

ALIGN IDOi OP ~II

:n-=1101.U N

~APT.

no.(/

USI THUi II>GIS OP WINO SIAM ON THI

UNDDSIDI OP WING TO LOCATI TENPt.ATI
IN A POJlWAJll) 011 An POSITION

• DITAILS CONTINUUI NIEXT PAGI

 35

© USI SOLDHlHO IRON OR OTHER

© CUT OUT HO... IN WDIG COVER
SUITABLE METHOD AND CAREFUU.Y
HL\T SUL THE CUT EDGE OP HOLE •

..

• REPEAT
THEABOVE
OPERATIONS
10 PLACES
ONEACH
WING
.

•
 36

•
NOTICI:
CUT AND HIA T SIAL TKB
DIAGONAL STRUT BOLT HOLES
IN THI WING COV!ll AT THIS
TIMI.

\. ..,,,,4;.,'
,,:,,
,,, DIAGONAL STBUT INSTALLATION

8
DIAGONAL
STRUT 40Zt4
,_ ..ell wtn11

•
,
1•75 CHANNEL
20080

, / 1• • 111•
SADDLI
20270
_%~

/
/ .
/
/ -- ~...,,

.....
,,

...

L '
#/ '>
• AN .. 11a
11HI • ~~-2la(l0!85)
 37
SEE PAGE33 FORMOREDETAILED
OVERALL
VIEW
•
••
,ua
IMSDT IN POCDT
ON nm TOP SIDI OP
::g,~cu ....

COMPR&SSSION STRUT
40210
( 1 EACHWING)

TRAILING £DOE
Of' WINO

•
POP TIii COMnaSSION STRUTS
INTO PLACI. (♦ PLACH, llACH WINO)

E>-------------------
NOTICE: THll VIP II INVIJITID P1ION THI AIIOVS vtl1I AND SHOWS THI
.....
TOP SUllPACI OP WING
PACTOllY CUT SLOT
IN RIB POCKET

INSlllT llJIS (I PLACU) ON TD TOP SIDI

OP WING AS SHOIIN. wtTH TD am TIP
IIISTING ON TOP OP THI TllAILIMG IDGI
SPAil. IP nm llU HANGS UP ON T1II
LIADINO EDGI SPAil NANIUVD rT INTO
POSITION AND PUSH INTO PLACI •

• 1utcc mes
OP WING
 RIB INVERTING - IMPORTANT 38

• UND&llSUlS vtn 0, am POCKET

WITH RIB INSERTED IN am POCltff ON TOP sms OP WING. CUT AND HUT UAL
TWO SLOTI IN TH& lllll POCJtff ON TD UNDUIJD& 0, WING Al rot.LOWS.

<D CUT ••• TBJlU ON&LAYO OP ctoTII CNLY. AffJlOXDCATILY 114• rOllWAJlD or
TH& SUM. CUT SLOT ••• 1, .. OPPOstn OIUGIN.Al. SLOT ON TOP sma or SPAR
THRU T1f0 LAYDI or CLOTH.

(D UMOVW am PllON POCltff AND TUU TIO am TIP a.- Al SHOWN.

(D U-INSTAU. JllB THRU TJD T1f0 ND SLOTS SO TIIAT TB& BUI TIP NOW USTS
ON TIU BOTTOM or TU TllAILING moa IPU.

© RIPS.AT THIS PROCSDUU ON TR& 4 INBOARD llllll.

• THIS OnllATlON WILL HE.PTO JtDP TH& 4 UCBOAaD JllBI nON VIBRATING OUT or TH11
am POCDTS AND lNTO TH& PllOnu.All. ANOTHD NSTHOD IS TO DRILL A SMALL HOLE
IN TH& TIP END AND SAnTY Will& IT TO TB& TllAU.lNG ll)Q& SPAil.
 39

• ·(DCUT COMPUHION
WING COVU

(D s1cua1:o~AJU>
WASIIUS Al SHOD,

<D:Olllll
ST80T 801. T NOUS IN TID
POa TU OUTBOAJU> STRUT Q!!l=L.

S'BOT lflT1l •01.TI

A 3/11" HOLElJI TKE(llT90UII) COK-

AND

l'lt[SSIOII S1RUTAfTIR LOCATJII&TIP STRUT

11.ANKAS SHOWN.NCTEr!P :mtl/1' IS 90
DEG.,O CIJF. STIii.iT.
©ATTACH TIP STaUr TO OVTBOAIDCOMPUSSIOII
·S'1'1Uf TO FIIIG&I. TIGll'l' OIILT.
© THI: TU' STIIOT HAI IXCl:SSIVI: 1.11:NGTR. TO DI:•
TEllNINS THS ,aol'D 1.11:NGTH.PUU. TU OUTBD
RtB OUT TAUT AS SIIOWII, HAU AND REHOV!.
NOTJCI:
© CUT OP'P IXCHSIVS UNGTK AND UR A RAT TAIL
PJl.lt TO FORM A "PISH NOUTH" ON THI: DID OP T1Q "?tSH MOUTH• IN THI:
THI: TIP STRUT. MOTi:: Flt.It IN THS SA.. Pl.ANS TIP STRUT MAY CUT IMTO
AS THll FLAT ON THll OTHO IIND OP TU TIP THI WING COVIR AND THIRI!
STRUT. ~ MAY Bl A SI.JGHT BOW IN
TH COMPRISSION STRUT.
(D llllMSTAI.I. THI: TIP STRUT ON TIii: COMPUIIION ) THIS IS NORMAi..
STRUT AND SADDI.I THI: "PISH NOUTH• ON THI
OUTBOARD RUI AT A to• ANGl.lt TO THI: OOT•D. IX.
COMPUSSION STRUT AS SHOWN HI.OW. (Tl:NIION ~
Wll.l. HOI.J) IN Pl.ACS!

© UPIAT STEPS 1• 7 01 OPf'OSITI WIIG.

FlU "FISH ltOUTH" IN TH! !lfD OF

TH! TIP ~UT. NOTE: Al.lCII
Pl.AT DID OP WlTH Ft.AT 1111>OF TIP snUT AS

•
TIP STRUT SIIOW. a0UNt>AND DIIUU SO IT
/ Wll.l. !tOT CUT SAIL.
1/4• 11 1•314" ClADl 5

';;Y

11.lNG EDCI
OPWlNG

OUTJIOARD RtB: PUU. OUT TAUT TO

DITSJIMINI TIP STRUT 1.11:NGTH.

NOTJCI: MAXI: SURI YOU

HAW ANPU 1.11:NGTHFOR
A TIGHT flT 11101'1 YOU

•
CUT 01'1' AND fll.E THI!
"FISH MOUTH• IN THI! END
Of THI TJ:P STRUT.
COMPRl:SSION STllUT I01.T HOU.
CUT AND HIAT SUI. 11:DGU OP ROI.It
 WIRE ASSY.
40

le.ER L.E. OOTIIOAP.0

- 21530
SN clat.11 •o•.

LOW£R - zmo
T.E. INIOAAO
s" at.ti ·a·.

!NBD~

OUTUO

TRAILING
EDGF.
/

~:-~
~
-~-E--,~ ~~~/
.9:>J
THIS ILLUSTRATION SHOWS THI ATTACHING

•
POINTS AND HARDWARE FOR BOTH THE UPPER
AND LOWER WING WIRBS. STUDY IT TlfOROUGHI.Y
ANO BECOME FAMILIAR WITH THE TERMINOLOGY
SUCH AS "UPPER LIIAOINO HOGB INBOARl>""LOWER
TRAILING EDGII OUTBOARD BTC. •

WIRES ARE ATTACHED AS MIRROR OPPOSITES

ON BOTH SIDBS OF WING.

l!ACH WIRE CARRIIIS A SLEEVE THAT INDICATES UPPER L. E. INBD. - 20580

ITS PART NUMBER.
~LEEVE.
DO NOT REMOVE THIS 9,__ __________ - detail "A" ..
LOWER iind UPPER T.£. INBO

A 20l1S
TO AXLB TANG
LOWER and UPPF.R L.E. INBOARD

Ft.AT TANG-20360
SHACKLE-20320
CLEVIS PIN-10440
SAFETY RING-20310

---- UPPER T .E. INBD

REF(D

• DETAILS GONTINIJED NEXT PAGE

 41

• Ul'PEK i&lld LOWER T.E.

LOWER T.£.
OUTBD
ANTI-DRAG
WIRE(80030)

~
OUTIU>ARD I:\
RBP\V RIP@
I.OWD L.I.
OUTBOAIUI

QADl5
10421

Ul'PER T.E.
OUTBOARD

REF©

I
1· 1t 114•
SADDLE
ZOZIO

REMINDER!
ALLVIEWS
ARESHOWN
UPSIDE
DOWN
.

• 1/4
11

(10420)
X -2 1/4
11
GRADE
5 \
\

1/4 X 2 3l4" GRADE

11
5
(10430)

•
 42

• AssembleANTI-DRAG

ANTI-DRAG
WIRE
WIREon both trailing edge spars as shown.

fl .,._-AN4-20a{l0170) Both T.E. spars

(8DD3D~
~ ~=
I I

T.E. SPAR

1/4" WASHERS
{10560)--~~
3 places

1/ 4" LOCKNUT
(10510)

•
• SPOILER ASSEMBLY
• •
The wings should nowbe tipped up onto the
nose for the next series of assemblies.
Face wings into wind and at about a 9D°angle
so they will not blow over. Tie-downsare
recoomendedto keep wings in place.

SPOILERON
PANEL
(70450)
4 places
HEAT
CUTSLOTS. SEENEXT PAGE.
SEENEXT
PAGE.

DIRECTION
OFWIND

TIE-DOWNS/
(IF BUILDING
OUTSIDE
AND
SUBJECTTOWIND)

~
(,.)
 SPOILER ASSEMBLY CON'T . 44

• SJ'OILEH l'OCKl:.,S
(4pi.u1

........._~\
SPOILER
PANEL
70450 .
(4 pllCHJ

SEE NOT!:
BOTTOM VIEW

LEFT WING
HORN SLOT
U PIIICHJ

© THI
INSDT SPOU.IR PANELS IN TH! SPOILER POCKETS.
"BIND lllDGI• IS OIUENT.IU) AS SHOWN.
MAKE SURE

(D CUT SLOT l-l/4" LONG IN THE WING COVER ANO HEAT SEAL THE
IDGIS. LOCAU TO ACCOMODATI THE SPOILER HORN AP-
PllOXUIATILY l-l/4" IN noN TH& EDGII o, TH& SPOILER AS SHOWN
uc Vlff am.ow.
(D ATTACH TU SPOILD CllOSSOVU PLATE 70430 WITH 3/11* 1t l/8"
POP lllVSTS II PLACHI. C!Nffll THI PLATE OVER THI SPACI
arrwu:it SPOU.&11S AND APPllOXUCATm.Y PLUSH WITH SPOILER TOP
IDG& AS SHOWN Bil.OW.

© AND
INHllT SPOIL&ll HOllN IUH IN THI 51.0T IN THI WING COVER
1.0CAT& ON TQ SPOll.UI AS Pill DtMENSIONS SHOWN. POP

•
lllVST TO SPOILlll ( 3 PLACISJ. SU NIXT PACI FOR HORN IN-
STALLATION ON lllOIIT WINO SPOU.lllS .

©
,.....
POP RIVET~
l/11" ll 3/1•
SPOILER HORN WI0
, l pLllcff) \ LEFT WING
'\
DllllCTION
OP S1'011.ER
ROTA,ON

LEFT WING SPOILERS

NOTE:
r.'\ "Bend Rids•• In th■ SPOILER:
\!/ ln ■-rt the Panelli (70450) H shown.

OUTBOARD

• ,0 SPOU.U
704SO
CllOSSOVIIR PLA TB

DETAll.S CONTINUED ON NIXT PAGE

FORWARD
 45
SPOILER ASSEMBLY CON'T .

• RIGHT WING

RIGHT WING SPOILER

In deployed po1lt10n r up,

TRAILING £OGE

DOWN

~
OUTIOAllD

•
CONPUSSION STJlUT
-DOWN

SPOll.D CONT1'0L
LINI TO 1£ ATTACHED
LATU.

ASSDmLI IUOHT WINO SPOIU1'111m SAG AS TD LOT lflNO

SP011.E1'S lXCIPT FOR THI SPOlUB HOIUC. TIii ATTACHING
RIVET HOU LOCATION Wll.1. H Dln'IJIBNT 4S NOTm> DIJ1t TO TIii
HORNS NOT IIINQ BINT IN RIOHT AND LDT HAND PADll.
NOTI: WHIN ATTACHUIO HOIUCAND CIIOSIOVU PLATU tT 1S
ADVISA8U TO DIUU, AND lllVIT ONI HOLi AND Al.ICM UNITS

•
8UOIII INSTALi.iMO THI lllMAINIMG arvns .
 46

•
T.E.

TRI-BAR
NOSE
...
,.
WIREASSEMBLY
(21600)
UP
~~
~'.....
ii
"
l
,1

..
..
~

L.E.

•
FWD

(◄\ATTACH TRI-BAR
TOROOT
TUBE
ASSHOWN
IN
\V(B).

® ATTACH
NOSE
(ADO
(A).
TOROOT
ANOTIGHTEN
TUBE
ASSHOWN
WIRE
DOWN
IN
HARDWARE.)
@ ATTACH
LOWER WING
WIRES
AN4-17's, WINGNUTS,
TOTRI-BAR
ANOSAFETY
USING
RINGSAS
SHOWN
EARLIER
IN TRI-BAR
ASS8-1BLY.

© TIP ASSEMBLY
ONTO
WING
POSTASSHOWN
ONNEXT
L.E. ANO
PAGE.
ADOKING

•
 • KING POST ASSY.
•
Pull out stakes that hold wings
downand rotate wings around
so KINGPOSTcan be installed.
T-HANDLE
PIN
(10472)
•
NOTE:Twist KingPost down so
all wires are completely slack. L. E. INBOARD
(20580) ------
KING POST l. E. OUTBOARD
(20570)----
CHANNEL
K.P.-75 T.E. OUTBOARD
(20560) ---
20070
I
T.E. INBOARD
(20550)
_,/

., ~ ... EYE BOLT

i~~-- UBETHREADS AN43-B15a

WHENKINGPOST
GETSHARD
TURN
TO
10370
FORTAIL "'
WIREATTACHI~
SAFETY
RING-f-.Mr
(20310) <~-..../
I ., SHACKLB
20330
( 2 places)

'
KING POST /~
(Twist Area)
40214

ROOT TUBE

, -----....
'
.,
• I I /4
UP
KING POST
NOSE WIRE
20595
I
INSTALL 3/16" WASHER
~•

WITlt
~\W'~
~
~a
• I

'

/~
\

/"
I
i/4~G
,~ ~~'\'\
S
/
~~
"~V;' ~()

.,

1
~,
~I
FORWARD TANG
INSIDEFORK J.""\ 20° TANG .,
~ 20350

~
~
 LANDING GEAR ATTACHMENT 48

•
Install SPOILER PULLEYSonto AXLESTRUTS, then
attach LANDING GEARASSEMBLY to ROOT TUBEas
shownbelow.
NOTE:PULLEY shownis LEFTside. Install
RIGHT side PULLEY
as a mirror opposite.

AXL
LEFTAXLE
STRUT TUBE CLAMP
430)
BUSHING{20240)
·Insert into pulley

,~AN3-7a(10020)
PULLEY(20230)
NOTE:WRAP
TAPEAROUND
AXLE
STRUTFORCLAMPING FRICTION.

AN5-46(10345)
WINGr«JT
(10525)
SAFETYRING{20310)·
NOTE:WASHER UNDER---- LANDING
GEAR
DOWNTUBE

• WINGNUT

TRUT
(ATTACH
TO SEEDETAIL
CHANNEL)
(2 PL.) ABOVE.
SEEPAGE18
Y RING{20310) FORATTACH.
DETAILS

ENGINE RE-INSTALLATION
RE-INSTALL
ENGINE
TOROOT
TUBE
WITH
THETWO
AN5-30aBOLTS
.

•
-
49

• FUEL TANK ASSEMBLY

Install fuel fittings as shownbelow.

FUELON/OFF
VALVE r-FUEL TANK
ELBOW(30270)
2 each
(30280)1

-:i....--
tf 1
'
RUBBER FUELTANK SEAL (30290) 3 ·each
Use oil to ease installation.

,..,,,- AN4-Sla(l0300)

1/8"x l" NYLON

If
NYLON WASHER
(20345)
REAR
VIEW

•
DRILLVENT
HOLES TO
1/16"/ 1. 5 mm

. )-\~-----:i;:;;:;;;:;:;:;:_--.....
FUELTANK(30251
Take FOAM STRIP(30205)and wrap
around ROOT TUBE(lengthof fuel
tank) then secure with tie-wraps. FRONT
VIEW
Install TANK to ROOT TUBEthen
attach fuel crossover line to
ELBOWS as shownbelow.
Drill oui existing VENT HOLES
on FUELCAPto 1/16 1. 5 11111
11
/

Both CAPand GASKET

CUTOUTHOLE
• FORBOLT.

ELBOW FOAMSTRIP
SECURE
WITH2 LG.
TIE WRAPS

•
SMALL
HOSE HakeLOOP in Crossover line ROOT
TUBE
CLAHP(30230) for easy water detection.
 50

• HEAT CUTTINGVELCRO DOOR

Before heat cutting, tighten king post and makesure
no wires are kinked on tangs.

VIEWFORBOTH
DRAWINGS
BELOW

@
Neatly heat cut hole on each
sail as shownso velcro door
closes snugly around king post .

•
NE
HEAT
HOLES. ~
RIGHT
SAIL~

®
Take filler cap off of gas
NEATLY
HEAT
CUT
tank and again neatly heat
cut hole for gas tank neck
so velcro door mayclose
properly.
7
~-----:--VELCRO DOOR
SHOULD

• CLOSE
PROPERLY
.
 51

• TAIL TO PLANE ATTACHMENT

AN4-16(10130)
Both sides.
l/4"Washer(l0560)
1/4" Wingnut(l0520)
Safety ring(20310)
-am:::::==0..i

AXLE
(Top view)

ANDLEPIN
472}bot u r
l boom

• UNTWIST
WIRES
KINGPOSTSOALL
ARESLACK.
(D Havea friend help lift
Tail Assemblyup onto all four
channels at once. SAFETYRING
(20310}
® While the LowerTail Booms
rest inside their channels on
the axle nut, install Upper Tail
Boomsto their channels with
T-HandlePins as shownin fig.@
® Nowthat UpperTail Boomsare secure,
go back and install LowerTail Boomsto
their channels using hardware as shown.
(4) Attach. UpperTail Wires to the KfngP~st and
Landing Gear Side Wires to the Flat Tangs on .
the trailing edge of the wings using SHACKLE,,:-;;-:>.
ASSEMBLIES. Nowtighten the King Post so /;,,.:'-._,_ \
all wires are taut. Before tipping ,/ \ ._._:::,
plane back onto its tail, BLOCK UP ,, ~~ \ i

•
TRI-BAR CROSSTUBE to prevent damage .._~--;:- ', ' f
to the Pulley mountTabs. '\;;:~.,, \ ~-
#
,,, ___ 49 ____ .,~
'
, •'-',
BLOCK
UPTRI-BAR
CROSS
TUBE
 52
• IGNITION WIRING/FUEL SYSTEM

NOSE GEAR ATTACHMENT

FORPURPOSE
OFCLARITY,
SOMEASSEMBLIES
ARENOTSHOWN
.

• SETPLANE
FORWARD
ONITS TAILAND
SECTION
ASSHOWN.
ATTACH
OFLANDING
GEAR

T-HANDLE
PIN
~72)
TOPVIEW
1-75 CHANNELS,~ E (40310)
(20080) t ERS_
NOSE
STRUT !
(40360) AN4-26 (10241)
WINGNUT
(10520)
AFETYRING(20310)
TENS
IONSTRUT
(41300)

•
I

DETAIL •A·
'LEFLEX TUBE AND 1) AN3-17a(10050)
2 reqd. l-(5
BRACKET ASSY. 2) STICK ATTACHTUBE/SPACER ASSY..
3) 1 x 1/4" SAODLE(20280)2 reqd.
4) 1 x 1/8" NY~ON
5) TELEFLEX
11
WASHER
AT1TACH
6! 3/16 WASHER(lO55O)
7 AN3-5a(10010)2 reqd.
8 TELEFLEX
(20345) 2 reqd.
BRACKET(7O6OO)
3/16" LOCKNUT(lO500)
CLAf·IP(70510) --i;=6
?IIIIIIIUIIIID:

9 TELEFLEX CA8LE(70470) "TAB"IN....-TELr'-

10) TELEFLEX CLAMP{70510) · •
11) 3/16" WASHER(l0550)
3/16" LOCKNUT
CLAf4P
TO
( 10500) NOTCH.IN
CABLE.·

NOTCH
TO
, I IN
"TAB.":
• I SEATMOUNT TELE.
' .$SY (80010) _CLAr-tP·.
STICKATTACH
TUBE(80120) 10-32 NUTFORMS
APPLY so· •
DRYLUBRICANT ~OC,!2!J:r:,il0495) _ _
TUBEMOVESFREELY
IN· ·
BUSHINGS
TELEFLEXNOTE:
7/8 NYLON
11
BUSHING---~ •THREADTHE10-32 NUTALLTHE
(70250) (4 EACH) WAYTOTHEENOOFTHETHREADED
PORTIONOFBOTHRODENOS AND
LOCKTIGHTLY.THISWILLPRE-
VENTEITHERENDOFTHERODFROM
GOINGBEYONDTHEMAXIMUMTRAVEL
ALLOWED.
TELEFLEX ATTACH
BRACKET
ASSY
(70600) - SEEDETAIL
A

10-32 NUT"STOP" SLEEVE

DDDHHIHID■H~ f iii !• 3~
Rod RODSEAL
l

Landing gear..
downtube

~
l "x 1/4"
Nylon
w;sher l"x 1/8"
( o346) Saddle Seat
@
EJ
IMPO.Tl SLIDE"LOOP
Of PUSH/PULL
OVER
CABLE
PUSH/PULL
END" /,;\ DRILLTHISHOLE
(20627)
TUBEPRIORTO
INSTALLATION.
ATTACH
SITEENOTOROOT TUBE
OPPO-
WIRE
~ SADDLES
ASCALLED
IN STILK,
ANDNYLONWASHERS
FORTO5/16" DIA.
•
~ (20270) support 00 MAINGEAR.
SHACKLE en
1/4" Locknut· t- ~downtube m
(10510) 8 (70350) )>
a:: OPPOSITE
ENDATTACHED
TO -I
Seat support downtube(70350) ROOT
TUBE ASSHOWN
IN
STRAIGHTENDHERE DETAIL
B 3:
i
~I
AN4-40a
(10340) ~ WINGMJT/SAFETYRING--.f~ AN4-15(10121)
0
C:
TOPVEW
(10520) (20310) '- •
Wingnutand safety ring
z
10520 20310
-I
Control Stick Grip(70580)
)>
Put on with hot water and soap. ~
THROTTLE ELEVATOR en
cable housing
See detai 1 on
CONTROL
ARM. en
OLE(2) 3:
'1ICIITVIfW
WHITE "THROTTLE CABLE •
~~-~ 1 rr--" .ATTACH" page.
ELEVATOR I
ANS-30(10332) PUSH/PULL
TUBE n
(80080) O 0
AN4-14·
-(10110) z
-t
COTTER KEY :a
(10635)install '◄ AN3-13a0
as shown. 00030) r
AN4-14 (n
l"xl/8 11 SADDLE ELEVATOR ADJUST· (10110)
(20270) /.., , ATTACH
HERE: TUBE(80110) WINGNUT
~$ WHEN
FLYING: 5/S"xl/16" NYLON (10520)
.- 5/1611 WASHER'
1-(; /16" THINLOCKNUT,-~
(10541) ✓
( DOUBLE.......,.,
ATTACH
HERE
HHEN
LYING
i-,.

SOLO_.:
,J

· :
I
:
WASHER (2) (20340)
AN4-15
(10121)
safety ring
20310
Two1/4.. Washers
3/16"x3/8" / T-HANDLE
PIN(l0472) :>:c'<..._ I
I :ASTLE
NUT(10521)
CLEVIS PIN (10440) SAFETYRING(20310) I
I AFETYRING(20310)
SAFETYRING(20310) 2 PLACES.
AN438-14a
EYEBOLT
(10350) 01
~
 TORQUE TUBE ASSY. 55

• 1. Slide the TORQUE TUBESPACER (91004) over the THROTTLE TORQUE TUBE(91003) and
attach the throttle cable mounting hardware and "travel stop" hardware as shown
in DETAIL A.

Throttle cable " ,.

. mount assm. ,(A) Travel stop
(EXACT CENTER~ assm. (A) FRONT'VEW
Throttle torque OF TUBE) / (looking from nose
toward tail )
tube (91003)\ • ~·-
I
-
I
- -

Torque tube spacer__:::::;:-----

- -
=
:E:I;'•-=-~~=--==-=-,_,___
~~
T~OmE LEVERS
I
ARE
_
'>
(91004) ATTACHED
IN LATER
STEP.

31

INDEX DETAIL A
0
29 90250 Cable swivel I 38
30 10550 3/16" washer
31 90260 E-Clip I
t • 3,~SEE NOTE
32 10375 An43B-23a

• !
33 91006 3/4" Alumn.spacer 35 I 0 39
34 10565 1/4" Fender washer 2
~
35 20270 1/8" Thick saddle
36 10560 1/4" Washer :J;
. - 37 10510 1/4" Locknut v-
38 10100 AN4-14a
39 20355 75 deg. tang
40 20360 Flat tang
41 10510• 1/4" Locknut ~,o
I

NOTE:SEEPAGE58 ANDSUB-ASSEMBLE
CONDUIT
THREAD
ADJUSTER
ONTO ~,1
TANGAS SHOWN.
2. Slide the 7/8" NYLONBUSHINGS (70250) into the TORQUETUBEMOUNTS (91002) as
shown(pay attention to proper "direction"). Slide each "sub assm." over the
the THROTTLE TORQUETUBEuntil 1t "butts" against the TORQUE TUBESPACER as shown.
TOP VIEW "Slots"- Attach ______ Thrott 1e torque
1 1/8" hose clamp tube (9100!)
Torque tube 0 0
mount (9100
....
......
..

•Cut 45° angle slot

in this bushing --.111
with hacksaw.
 -+,:_~
1
MOUNTING SEA TS 56

•- IMPORTANT! Before starting, place SEATMOUNT

its forward position on the TRI-BAR

are 1/8"(3.2 nm) from the NOSE

ASSEMBLY
CROSSTUBE.~~---
(D Align·seats·· later·a11y as shownin fig. 1 below.
® Slide both seats fontard until their outside corners
STRUTS as shownin
fig. 2 at ri..9..ht.BESUREseats are still aligned
in
®
TOPVIEW

laterally._ Q) With seats aligned, use predrilled

holes in seat mountto drill eight 1/4"(6.4:nm)
holes in seats and install hardwareas shown
on next page.

®
Seat support down-..
tube (70350)
DRILL3/16"/4.Bmm
DIA. DRAINHOLES
Seat (70365) (4 PLACES)

1
Predri 1led 1'- Ori11
Seat mountassm. holes~ 1/4" (6 .4 mm)

•
(80010) 0
0
------.:.lit',------a:~,_;t,,P holes a places

DUCTTAPEENTIRE
PERIMETER
OFEACH
SEATTOPROTECT
SEATCOVERS.INSTALL
EACH
COVER/CUSHION
OVER
SEATS
ATYOURCONVENIENCE.
G)
Seat
(70365)

,,

• Seat mountassm..
(80010) EXACT CENTER:Use two OUTSIDE pre-
drilled seat mount holes (forward
crosstube) to measure from.

~ FRONT VIEW
 MOUNTING SEATS CONT.
Install hardware as shownin sequence. NOTE:Steps 1-4 are for reference only
57

• and will be installed later .

The same hardware is used to install both seats.
110030 AN3-13a2 reqd.
• 2 10550 3/16" washer
3 10500 3/16" locknut
4 91001 Throttle lever assy.
}
ONLY.SEELEVER
REFERENCE THROTTLE
ATTACH
PAGE.
5 80010 Seat mount.assy. • AN4_ a (In lever throttle
17
6 10120AN4-15a ( 2) kit).
7 10565 1/4" Fender washer
8 10560 1/4" Washer
9 10510 1/4" Locknut
10 10140AN4-16a
11 10565 1/411 Fender washer
12 10560 1/4" Washer
13 10510 1/4" Locknut
14 70365 Seat
15 10120.AN4-15a
'(l in lever throttle·kit).
16 10565 1/4" Fender washer
17 10560 1/4" Washer
18 10510 1/411 Locknut
19 10150AN4-17a
20 10565 1/4" Fender washer
21105601/4" Washer
22 10510 1/4" Locknut
23 70330 Seat belt set •

• Install male and female

belts together.
24 91003 Throttle torque tube
25 30470 1 l/8 11 Hose clamp
26 91004 Torque tube spacer
27 70250 Nylon bushing
28 91002 Torque tube mount

23
REFERENCE ONLY
Levers attached later.

1 l/8 11 HOSECLAMP
11
goes around
slotted torque tube mount"
to create friction control for
adjusting throttle stiffness .

•
 58

• THROTTLE CABLE ASSY .

INSTALL
THROTTLE
CABLE
ASSHOWN
BELOW.

G) ®
ADJUST
CONDUIT
THREAD
ADJUSTER
SO INSERT
CABLE
BARREL
INTO
THAT
THREADS
AREALLTHEWAYIN CABLE
SWIVEL

@ ~~--~d:I
BEND
TANGSOCONDUIT
GOES
STRAIGHT
INTOCABLE
SWIVEL

SIDEVEW SEAT
MOUNT
ASSEMBLY TORQUE
TUBE

•
THROTTLE
CABLE
STANDOFFS
SEEBELOW.

® SEATSUPPORT
STAND-OFF
OOWNTUBE
l/2N {l. cm)--.-

SMALL
NYLON
TIE WRAP
THROTTLE
CABLE
*CUTTHREE
PIECESOFFUELLINE1/2" (1. cm) FOR
STAND-OFFS~
SECURE
THROTTLE
CABLE WITH NYLON TIE
WRAPANDSTAND-OFFS
TOSEATSUPPORT DOWNTUBE AND
• LEFTLANDING
GEARDOWNTUBE
ASSHOWN.

SEENEXT
PAGE
FORTHROTTLE
CABLE
INSTALLATION
TOCARBURETOR.
 ~ 59

. THROTTLE CABLE ASSY. CONT .

------
Take off CAPof CARBURETOR.
(Be careful of SPRING
out). Insert JET NEEDLE
then take CABLE BARREL
popping
and insert it through hardwareas
ADJUST
SLOP
OUTOFTHROT-
downthrough center hole of SLIDE, TLECABLESO
SLIDEWILL
shown.Secure CABLE BARREL in SLIDEas shownin detail at RESTONIDLE
right. Take completedassemblyand set into CARBURETOR SCREW.---
BODY and secure CAPwith SCREWS. Nowadjust slop out of IDLESCREW
THROffiE CABLE with conduit thread adjusters on CAR-
BURETOR CAPand SEATMOUNT TUBE so the CARBURETORSLIDE
rests·on top of IDLESCREW as shownin diagram at right.
//

~ Attach CLIPin center slot.

NEEDLE
POSITION
CLIP__.~~ For LEANER setting place clip
in upper slot.
DUST
COVER For RICHER setting place clip
JET NEEDLE - in lower slot.
(INSERTTHROUGH
CENTER~OLEOFSLIDE)
~ CABLE
BARREL

•, ~JUST SLOPOUTOF --- ----,

THROTTLE
, CONDUIT
CABLE
WITH
THREAD
AO- SLIDE
_ I
1 _
J•
i ~~STERS
ONCAPAND
LEAT MOUNT TUBE.

..
..
..
..,.::----
,.

CABLE ,:j,
.. -
::~u-
BARREL
-.{~_; JET NEEDLE
COMES
~ SPRINGI - THROUGHHERE.

~
~--SEAT

• i _ ___, lARBURETOR SOOY

 60

•
THROTTLE CABLE ASSY. CONT .
Before starting on this page, check
again that procedures on the pre-
ceeding page have been done cor-
rectly. •

~ Rotate TORQUE TUBE

\!..) completely forward.

TORQUE
TUBE
. OWER
STOP

@T;.SLIDE will
most likely not go
all the way up to
the top of the
THROAT.

®8end LOWER STOP

•
TANG downas need-
ed to have the
SLIDElevel with
the top of the
CARBURETOR THROAT
to achieve full
throttle.-------

• * The AIRFILTERshould be installed after the above procedure

is completed. Refer back to the "CARBURETOR
for hardware.
ASSEMBLY" page
 61

• ©
THROTTLE CABLE ASSY. CONT .
Assemblehardware in sequence shown.
® Take only ONEof two lever throttles and bend in vice between two pieces of
woodto the specifications shownin detail "A~
@ Install Lever grip balls on both lever throttles
Rotate Torque ~ube complttely for-.-ard{when
as shown·in detai 1 8
lower tang bottoms out on seat
11 1
:

mount assembly). Then place Bent lever thro~~le on the left side of torque.
tube. Sit in left seat and adjust lever throttle so your hand comfortably
clears the lower wing wires at full throttle as shown. With lever throttle
in place, mark and drill 3/16"{4.8 nn) hole in torque tube using holes in
lever throttle as guides. Install hardware as shown.
Repeat mountingprocedure for right hand throttle.
. CAPSCREW 3/8"0IA.
®--n1s· ® (10391) both levers

II
II "
II LEVERTHROffiE
(91007)
LEVERGRIP~

T fiQIE: BEND
ffiERONL'f
ONETHROffiE (90499) both levers

• --------0 l
BEND POINT
4"(100.ITITI)
0

© FORWARD
Sl)EV£N

~ WITHTORQUE
,,-~
TUBEROTATED
YOUR
HAND
COMPLETELY
SHOULD
COMFORTABLY
FORWARD,
-,
\ /
\I \
\
CLEAR WIRES(about2"/ 50. 1m1)
LOWER

\ \
\ I
~------~
~- •~ SEATMOUNT

• AN3-13a(l0030J~
2 p1aces
3/16" Washer(lOSSO)
3/16" Locknut{lOSOO)
LDRILL3/16"(4.8 1m1)HOLE
HARDWARE
ASSHOWN.
ANDINSTALL
 TE!FLEX
~STALLTELEFLEX
~ Attach TELEFLEX
CABLE ROUTING
CABLE BYDRAWING
CABLE
SEQUENCE.
to TRI-BAR
stand off and secure with LARGE
CR0SSTUBE
NYLON
•
with small piece of FUELLINEfor
TIE WRAP.
•
@ RouteTELEFLEX CABLE
11
as shownin drawingB then secure CABLE along LOWER TAIL
BOOM with three 6 VELCRO TJES. Secure CABLEagain on TAILBRACE with 611 VELCRO
TIES.
@ Final assembleTELEFLEX
• --CABLEonto RUDDERBRACE and RUDDER CONTROL ARM as shown
.

FRONT
VIEW
~LANDING GEAR
SIDEWIRE
LANDING
GEAR
TAILBRACE D~NTUBE
NOTE:IF AIRCRAFTIS I
NOTTOBE11BROKEN 6 VELCRO
11
TIE(70575)!
· D0WN11
OFTEN,
USE 4 places
TIE WRAPS. SEENOTE ROUTE
TELEFLEX
THROUGH-HERE

3/16·w X 3/8°
CLEVIS
PIN
(10440)
TRI-BAR ►/ J TAILSKID ½·
~
'<~
CR0SSTUBE
LEFTSIDE f~ RUDDER
BRACE
LARGENYLON
TIE WRAP
(30490) RUDDER
CONTROLARM
DRILLCLAMPTO1/4" DIA. USEAN4-2O ~ ;,- SAFETY RING
(10180), WASHER,
WINGNUT& SAFETY
RINI (20310)
10-32 NUT
FUELLINESTANO
OFF FORMS "LOCKNUT"
TELEFLEX
CABLE
~ AGAINST FORK
TELEFLEX
CABLE O>
I\)
 63

• SPOILER LINE.ROUTING
PULLEY ON
COMPRESSION STRUT

USE THIS TYPE OF KNOT ON

BOTH INDS OF SP011.lll
THI! SAMS SHACXU,
CUVIS PIN AND SAFSTY
@ © CONTRO1. t.lNES.

PIN AS OTHIDl DID OF

CONTROL CABU ON
PULLEY
ON
Tld TIU-IAll lllACHT. AXLE
STRUT
PRON lllOHT
HANO SPO~
HOI\N
(AXLE
STRUT ©
• PULLEY)

FR
ON.
,o· G) TIE KNOT
SHOCK
IN ENOOF
CORO(70435)
U POL.I.EV
lllQHT HAND
T PIDAL
ANOSLIPTHRU LASTHOLE IN
SPOILER HORN.TIE OTHERENDTO
THRU PULLIY
Lll'T HAND
ON TOLOOPIN SAIL. 00 NOTOVER
FOOT PIDAL\ TIGHTEN.WITH SPOILER
IN CLOSED
POSITION,J..INE
SHOULDONLYBETAUT.
TRIMENOS {!Y .

® ATTACH
LINE°
SHACKLE
ASSY.TOUPPERMOST
TOSHACKLE°.
HOLEIN SPOILER
HORN.TIE ONEENDOFCONTROL

@ ROUTE
AXLE
LINE~OMHORN
STRUTC, THRU
THRUPULLEY
ONCOMPRESSION
PUIY ONTRI-BAR(SAME
STRUT (a), ~RU PULLEY
SIDEASHORN} D , THRU
ON
PUL-
LEYONSAMEIDEPEDAL , ANOFINALLY TOSHACKLEASSY.ON !LOT'SSIDE

• TRI-BARTAB ASSHOWN
IN UNPRESSED
UPPERWING
11
A OVE. ONLY
11
USEBOWLINE
STATE,PULLLINEUNTILSPOILER
SURFACE
AHO TIE. REPEAT
KtWTS
"OPENS"
ONOTHERSIDE.
ASSHOWN. WITHPE~AL
1/16" (1.6 nm} FROM
 64

• BRAKE SYSTEM COMPLETION

ATTHISTIMECOMPLETE
ASSEMBLY
YOUHAVEALREADY
THEINSTALLATION
INSTRUCTIONS
COMPLETED
CERTAIN
OFTHEBRAKE
IN THEMXIIBRAKE
INCLUDED
SYSTEM. 00 SOBYCONSULTING
KIT#91222(SEPARATE
SUB-ASSEMBLIES,
SOREAD
INSTRUCTIONS).
THEINSTRUCTIONS
COM-
PLETELY
TODETERMINE
WHATSTEPSAREAPPLICABLE
.

•
 REDUCTION ASSEMBLY - 65
•
REFERTO THETWOFOLLOWING
PAGESPRIORTO ASSY
AFT END OF ROOT
Slip PILLOW BLOCK onto DRIVESHAFT TUBI ASSDCBLY \
before assembling any other
hardware.
AN7-2la ROOT TUii
BRACKET
10349
(2 ,._,
HS40
INVDIT OPPOSITS
BOLT .U IHo.N

$I
1111• - 20 z ~"
10504
( 2 pJaceaJ---

• + I' I

~
65 FT. LBS.
,_ __ t:CCENTRIC
LOCK COLLAJl
(2 PLACES)
AFTER ASSEMDLY USE A
DRIFT PIN TO TURN TH£
COLLAR IN 'rHE DIRECTION
AN5-1'1a 01' SIIAFT ROTATION ANI)
10321 LOCK IN PLACI! WITII SET
(l Placu) SCREW 40 IN /LBS
MOUNT THI
CENTIR BOLT
lN THI OPPO-
SITI DIUCTJON
AS THI TWO OUT-
SIDI BOLTS FOR
PROPU BALANCI

•
 66
DRIVESHAFT/BEARING ASSM.
• INSTALL
ECCENTRIC
LOCKCOLLAR
ASSHOWN
BELOW.
UPPER
DRAWING
FORREFERENCE
ONLY.

BEARING LOCK-COLLAR
Factory installed and
torqued to 70 fn/lbs.
(7.7 N•m)
SIDE VIEW

FORWARD

• TORQUETO
240 IN. LBS.
FAFNIR
RAK-1
PILLOW
BLOCK(60016)---r
IMPORTANT: Rotate Eccentric Lock-Collar
in DIRECTION OFSHAFT ROTATION(counter
Use DRIFTPIN punch to set clockwise, when standing behind drive-
Eccentric Lock-Colla~ shaft looking towards nose of aircraft)

Loctite and torque set screw

to~ in./lbs. (4.4 N•m}
NOTE:PILLOW
BLOCKMUST
BE
PARALLEL
WITH
ROOT TUBE

• Eccentric Lock-Collar
AFTER
FINALADJUST
.
•.

67

•
11 ,ao,: HAS IXCISSIVS RUN OUT, TIGHTIIN
WING lil'AR
J NUTS TOWARDS ONI TIP oa THI OTHO TO
TRAILING EDGI
BIUN0 BOTH TIPS DITO HOPIR TJlAClt.

PROPU.Ua
(30344)
NOTE:PROPELLER
THICKNESS
MAYVARY.
l,-,-ALIGN THI 2 PULLUS WITH A1"4-Z4e - 10320
USEWASHERS
ASREQ.
1 A STRAIGHT IDGS ON BOTH (I Plac:H) (LOCKNUTS FACING TAIL)
I fACIS. PROP HUB
.. ,.-up-.e)

0 0
LOUR lNNla I.OCKNUT
(Ref. 2) DIUVII SHAn
COUPUR
lllef. II
DRIVS SHAn

•
INGINI

PILLOW BLOCK
INll (Ref. 21 AN5-20a/
10323

( 1) SLIP 1'111 Pia.LOW BLOCK IOOll ON THI DRIV! SHAFT ANO

VISUALLY CIHTIR IT UNDER THI ROOT TUBI BRACKET

...,.
MATCH.ID
HI.TS
IH40 SICURI IN PLACll WITH ALL ATTACHING HARDWARE
AS sHnwN. SEEPREVIOUS
PAGES
.
1/.
•( J2rrm"2) SLI0II THI ICCINTRIC LOCK COLLAR ON THI DRIVE SHAFT
• /\ TO THI POSITION WKU! IT INGAGIS THI CAk ON THI
DIPUCTION PU.LOW BLOCK INNER RACI. ROTATE THI COLLAR UNTIL
(Ref. I) IT SLIDES OVIJI THE CAMklD END OF THI INNER RACE.

APPLY FOIi.Ci IN THI CSMTD

OP SPAN LIM0TH. ( J) APPLY LOCTITI TO INNER BORE OF THI J• PULLEY ANO
SLIDI IT ON THI DIIIVI SHAFT. SICURI WITH l BOLTS:
MOUNT THI CllNTl!R BOLT IN THI OPPOSITE DIRECTION
NOTI: MARK THI BILTS IN SIQUINCI 11·2•3-4) AS THI OUTSIDlt BOLTS FOR PllOPIII BALANCI. TORQUI
AND ALWAYS RI-INSTALL IN THI SAMS OIi.Dill. TO Ml IN.LBS.
RICO ....... DID BIi. T TIMSION:
DAYCO-JVX251 •y• BU.Tl (4) APPLY LOCTITI TO THI INNlt.R 80111 OF THI! I" PULLEY
AND SLIDI IT ONTO THE PROP. SHAn. MOUNT BELTS
I LBS. lNITlAJ. JI MIN, BRIAlt-lN AND ALIGN THJI 2 PULLEYS WITH A STRAIGHT EDGE AS
1-1 LBS Att'rla BRIAK·IN SHOWN. ATTACH PULLEY WITH 2 BOLTS MOUNTED IN

• GATU••JVX2 .. ■v• HI.TS .

7 a.as. lNITLU. JO MIN. BRIAlt-lN
4-1/2 1D 1-1/2 LBS. APTIR BRIAK•IN
NOTI: TIii Bil.TS COMI IN MATCHID SITS.
IF DAMAGaD Rift.AC& ALL FOUR BIL TS
~PPOSITB DIIIICTIONS (FOR BALANCE), 65 FT. LBS.
{5) ADJUST BU. T TllNSJON AND LOCJC PILLOW BLOCK IN PLACI.
(6) ATTACH PROP AS SII0WN AND TORQUII NUTS TO'TO IN.LBS,
 68

• BEARING LUBRIC.ATION

Note: Too muchgrease 1s as bad as not enough.

BOTH
the drive shaft and prop shaft bearing MUST
BEPERIODICALLY
RELUBRICATED
to assure long life. The bearings should be lubri-
cated EVERY
50 HRS.OFOPERATION
and 30 hrs. if operated in ex-
treme dirt/dust environment.

REMOVE
the propeller and use EXTREME
CAUTION
as the bearings ideal-
ly should be lubricated while in operation (run engine at idle and
DONOToverspeed).

• Feed the specified lubricant into the-bearing SLOWLY

"bead" (of lubricant) forms around the seal.

PROPER
LUBRICATION
OF BEARINGS
PREVENTS
EXCESSIVE
WEAR
OF PARTS,
until a slight

PROTECTS
BALLRACES,BALLS,ETC.FROM
CORROSION
ANDHELPSIN DIS-
SIPATING
INTERNAL
HEAT.
SPECIFIED LUBRICANT ONL YI
USEONLYA LUBRICANT
CONFORMING
TOA NLGIGRADE
TWO
CONSISTENCY.
IDEALLY BASED
A LITHIUM LUBRICANT.

TUBE CAPS
Tube Caps: Be sure to install the tube caps and it's recon111ended
that the caps
with a loose fitting be pop riveted on with small 1/8" rivets.
The following tubes receive caps:
7/8" TUBE CAPS,ONEIN EACH ENDOFTHE:
1. TAILBRACE TUBES.
2. RUDDER BRACE TUBE. l".TUBECAP
3. STABILIZER T.E.

• 4. ELEVATOR
5. TAILSKID
L.E.
6. L.E. OFTHERUDDER
BOTH
ADO
L.E.
ENDS
&
LOWER
APPROPRIATE
T.E. WING
TAILBOOMS
SIZEPROVIDED
SPARS
TUBECAPSIN

MUFFLERASSY.
FIG.A Assemblehardware below by
sequence and notes.
1) AN5-2la (10331)
2) Fender washer(l0600)·2·needed.
3) Rubber gronment(30380)4 needed.
Note direction of•ffrsl: anc1·1ast
njpples. Cut off center nipples.
4) Muffler attach strap(61042)
5) Muffler bracket.
6) 5/16" Locknut (1054.0)
Repeat steps 1-6 for· other side.
69
7) AN4-27 (10260). Use FIRSTHOLE
AFT-ofseat support downtube
·hoTe. Assemblehardware as shown.
8)_l"x l/8 11 Nylon washer(20345) 2 reqd.
9) 1/4" Washer(l0560)
10) 1/4" Locknut(lOSlO}orWingnut (10520)
FIG. 8 Take MUFFLER and join together
to EXHAUST HEADER, attach SPRINGS to tabs
then SAFETY WIREto tabs and route wire
downthru center of SPRINGS and fasten
to tabs at other end.

,/' .. EXHAUST HEADER

(61045)
MUFFLER~
SPRING SAFETY WIRE
(00938790) 2 places

•
NOTE:# 10 WINGNUT
lsuSED ONLY\~HEN
"QUICK" BREAKDOWN
IS NOTUSED.

lMUFFLER -~
(61041)

B
BACK VIEW
Cut off nipples
on the 2 center
gromnets.

•
MUFFLER--.._.
(61041)
 70

• TAIL BOOM •PINNING•

THISSTEPMUSTTAKEPLACE WITH THEAIRCRAFTIN A COMPLETED
FORM(LESSTRIM
TAB,ENGINERUN}
ANDKINGPOSTTIGHT ASDESCRIBED IN THEMXIIOWNER'S
MANUAL.
CAREFULLY
LOCATE,
CENTER PUNCH ANDDRILLASSHOWN BELOWEACH
TAILBOOM/TAIL
MOUNTANOPINWITH3/16" x 1-7/32" CLEVIS
PIN (10457)ANDSAFETYRING(20310).

•
/SAFETYRING
ct'(20310)
STABILIZER
L.E.
TAILBOOM
~~II
11
3/16 xl7/32"~ \
CLEVIS PIN / C/L
(10457) ,,
DRILL3/16 /4.8 llll1 HOLE
11
THRU
FORWARD BOTHSIDESLEVEL &DEBURR
SIDE VIEW (1 PLACEEA~OM ASSY)

•
 71

• TRIM TAB KIT ADDITION

ATTHISPOINT,CONSTRUCT
FOLLOW
THESEPARATE
ANDADDTHETRIMTAB(CONTROLLABLE)
ASSEMBLY
INSTRUCTIONS
PROVIDED
WITHIN
TOYOURMXII.
THETRIMTABKIT.

TRIMTABNOTE:THISTABIS ONLYINTENDEDTOAIDTHEPILOTIN COMPENSATING

FOR
VARYING
C.G.'S ASA RESULTOFFUELBURN-OFF
ANODIFFERENT
PAS-
SENGER
WEIGHTS. YOU MJSTSTILLMOVE
THESEATS FOREANO
AFT,
DEPENDING
UPON THE[oAoCONDITIONS
.

•
 72

• WING WASHOUT

LIVll. ON IIOOT TU■S

L&Va. ON S1'11AIGHT IDOi
PROM LIADlNO IDOS SPAii TO TIIAILINO
aooa SPA& AT THS WlNO TIP.

LIVIL AIACMn AND BLOCIC INTO POSITION

TO CIT A LIVSL RSA.DINO AT ROOT TUBE.

THI TRAILING IDOi SPAR SHOULD

81 APPROX. ONI INCH HIOHER THAN

1Do■_s_•_A_•_~r~~~~~~:l~:~:::~~~~~~~~~:~-----:.._
• \
\DING
UWL

TOUCH BOTH SPAii

__
TIPS,~
T_H_•_1._u_D:1:N:0:::1:D::0~1CslP_A_R_A_T_TJHL1

LtOHTLY WITH STRAIGHT IDOi

w1No

STJlAIOHT SDOI

(D LBVEL AND BLOCJt THll AIRCRAn AS SHOWN ABOVI TO GET A LIVl!L Rl!ADINO ACROSS THI!
ROOT TUBI PORWAIID AND APT.
(D USI SAKI LIVIL ON A STRAIGHT !DOI TO CIT Rl!ADlNO AT WINO Ti,S FORWARD AND AFT.
AS SHOWN ABOVI.

CORRICT WINO WASHOUT IS AN lNPOIITMCT PACTOII IN THI STALLING CHARACTERISTICS

AND LOW SPUD HANDLING OF YOU& Al&CllAFT. WASHOUT IS srr AT THI PACTOIIY THROUGH
PHCISI WIU LSNGTHS: HOWIVS&, IT SHOULD aa CHl!CKID auoaa PLIGHT TO 81 CERTAIN
THAT TRI ANOLU Alli WITHIN PACTO&Y SPICtnCATIONI.

CDMAU suu THS ICING POST IS ADJUSTSD AND ALL THI SLACK IS OUT OF THI! WIii.iS.
© CHICK ALL Wl&II POil IMPIIOPU LOCATION, TWIST ETC.
WASHOUT AT TIU TRAILING IDOi Al'X. I"

• r, PllOBUMS occua FUL PllD TO CONTACT YOUR Dl!ALIR.

 • ROTAX 377 & 503 ENGINE BREAK-IN PROCEDURE.
The break-in period must be done with the engine on
the aircraft and loaded with the prop.
• CAUTION! During break-in whenthe engine heats up
• \

it will want to accelerate from about 5000 R.P.M.

Tie off AXLE(NOT TAIL)to secure aircraft from to 6000 R.P.M. The engine will be running DANGER-
rolling forward or place aircraft up against bldg. OUSLY LEAN and mayburn up. The throttle must be
Be CAUTIOUS of persons and objects in the reduced back to 5000 R.P.M. every time the engine
PROPBLAST AREA. wants to speed up.
Use the graph below for break-in time/ R.P.M. IMPORTANT.
Use a BIA TCW rated oil with the fuel ONLY!. After en~fne co_o_l
s-,-re---t-or_q_u_e_c_y-:-1-:-1
n~d:-e-r
""'!'h-e-ad
....
s....,..to---,,2=2~0
The FUELto OILmixture ratio should be 50-1. in. lbs. (24.5 N•m)also re-tighten exhaust header bolts.
(ENGLISH) 5 gal.FUELto 13.8 oz. OIL. A final note is to adjust the idle after break-in.
(METRIC) 20 1. FUELto 400 ml. OIL. Adjust SHALL SCREW for smoothidle and adjust the
LARGE SCREW for idle speed. •

10 15 20 30 l 2 2
FULL THROTTLE "" .....
71
- --- ------ - --- sec
---·
.... ---·
-- ---·
sec
..... sec. sec
--
--""-· min.- min.
......

-- --
-. ..... 11in.
~ 7
- -
61

-
i 6
I-
1 ....
5
-
'

-
1 5 5 5 5

-
5
0
-
1
,- ,--- ,--- ,----
---- -
5

-
0 5
0
,- 4 1
,-- -
5 f 5
4
X

~ 3
- 5 5
5
111'1111 -
'3
0.: '
a: - -
2
~

1
....
1
-
l
-1 ....
1
......
l
...
1
.....
l
....
1
...
1
.__
.!.
'2
I-
-
1 1
I-
OFF -
MINUTES

~
(,.)
 74
WING/STABILIZER. INCIDENCE

• This procedure ma not be necessar. The aircraft must first be flown

a nonna cru1se spee to see 1t wants to pitch up or downw.ith
hands off the stick. If this 1s the case then SHIMSTABILIZER accordin9ly.
If aircraft wants to pitch up, ADOwashers to leading edge stabilizer.
If aircraft wants to pitch down, ELIMINATE washers from leading edge
stabilizer. See below for details.
\~~!iling edge
WING \bilizer

C l
STJlAIOHT ltDCI BOARD l/4" CREATIJR
THAN •x•
OR IQUIVALINT
N&ASURIMIINT

SHIN BltTWUN SPAR AND TAIL MOUNT

AS/NICltHARY
(Rel. 5)
STABU.IUR L&ADIJIIG
IDOi Sf'AR

• TAIL MOUNT

0 TO MIASUJll THI INCIDDCI, WIIOHT TIU NOSI WHUl. TO THI CROUND SO

THAT THE UPPU TAIL WlUI AAI TAUT.

CDMAKEIUU THE ICING POST II ADJUS'Tfl> TO IIDOW ALL SLACK PROM

WIJllS.

© tHI
PLACE A STRAIGHT EDOI ACROSS THI BOTTON OF THE WING SPARS NEAR
ROOT OF Ttu WINO. THI STRAIGHT IDCI SHOULD LICHTl.Y TOUCH
BOTH SPARS AND CONTllfUI IACIC UNDER BOTH STAIILIUJl SPARS. (2
PIOf'l.S ON THIS OP!RATION.)
© LIADINO
STAIU.JUR TRAU.JHG EDQE SHOULD IE l/4" HIGHIJl THAH THI STAIILJZIR
EDCll.

© 1,SHJ.M
YOU DO NOT CIT THI PROPSR DlFFllJIINCll. IT WILLaa NIC!SSARY TO
THll STABU.lUll SPARS WITH WASH&RI TO ACHJ&VI THI PROPI.R ANOU.
© AU
LONGER BOLTS ,U.4-.54a) AND IXTRA t/4" NYLON WASHUS
PROVJDIO JH KIT ,OR THIS.

NOTS:

•
DO NOT NICLICT nus PROCEDURI. IT
HAS AH arnCT ON FLICHT PERFORMANCI.