Summary

 

Manuals

All manuals on this page can be searched by pressing Ctrl-F or ⌘-F, or alternatively select from one of the following categories:
Engine Maintenance Manuals
Engine Overhaul Manuals
Cold Start Installation
Maintenance Persons Information
Troubleshooting Strobe Systems
Engine Installation Manuals
Engine Parts Book
Propeller Manuals
Aircraft Technical Manuals
Pilot Operating Handbook
Standard Wiring Practices
Tail Pipe Fitting into Muffler Body for Non-Jabiru Airframes
Throttle Cable Kit
Airframe Constructors Manual
Card Diagrams

Click here for a list of avionics & instrument repair/calibration service centres in Australia.
Click here for owners/operators responsibilities for continued operational safety monitoring.

Engine Maintenance Manuals

Engine Maintenance Manual (Revision 7, June  2016)
J5100 Engine Maintenance Manual (Revision 3, June 2010)

 

Engine Overhaul Manuals

DRAFT - Generation 4 2200 / 3300 Overhaul Assembly and Parts Book - DRAFT ONLY
2200 / 3300 Overhaul Manual (Revision 11 November 2016) CASA Approval Pending

 

Cold Start Installation

Cold Start Installation Instructions

 

Cold Starting Checklist

 

Maintenance Persons Information

Summary of Significant Engine Changes
Click Here for Procedure for Cylinder Head Modification for CHT Sensor Installation

 

Troubleshooting Strobe Systems

Trouble Shooting Strobe Systems

 

Engine Installation Manuals

J2200 Engine Installation Manual (Revision 8 October 2015)
J3300 Engine Installation Manual (Revision 6 October 2015)
J5100 Engine Installation Manual (Revision 1 June 2009)

 

Engine Parts Book

J2200 Hydraulic Lifter Engine
J2200 Roller Cam Hydraulic Lifter Engine
J2200 Solid Lifter Engine
J3300 Hydraulic Engine
J3300 Roller Cam Hydraulic Lifter Engine
J3300 Solid Lifter Engine
J5100 Solid Lifter Engine

 

Propeller Manuals

 Propeller Technical Manual Issue 4 12th May 2014
2200 and 3300 Jabiru Scimitar Propeller Manual Issue 5, 8th June 2016

 

Aircraft Technical Manuals

J120, J160/170, J230 Aircraft Technical Manual Issue 8, 28th March 2017
CASA Approval for J160C Pending

 

Pilot Operating Handbook

J160-C
J160-D
J170
J230
J120

 

Standard Wiring Practices

Wiring Diagram All Models

Tail Pipe Fitting into Muffler Body for Non-Jabiru Airframes

Tail Pipe Fitting

Throttle Cable Kit

Throttle Cable Kit

 

Airframe Constructors Manual

Welcome to the Constructors Manual page!

In these Manuals you will find all the instructions that you will need to build your very own Jabiru, one step or task at a time. Each task in these Manuals stands alone, with the intention that each task will be completed before you move on to the next task. There are many good reasons for this approach: you can easily keep track of where you are in the build; it forms a checklist to ensure that nothing gets overlooked; and in many cases a task will be dependant on the completion of a previous task and if the sequence shown in the Table of Contentsis followed there will be no issues of this kind.

The Table of Contents of this Manual is also the Build Sequence.

The Constructors Manual is being written and updated on a continuous basis and the information on this page will be regularly updated. In all cases the version of each task or Manual is the date in the footer, where the latest date is the current version, so if you have downloaded a task and you want to check if there has been an update just check the date in the footer.

There are 6 model-specific Constructors Manuals listed below. They are reasonably large (~25MB) .pdf files that have been optimised for fast web viewing: click on them to view or download. Each Manual has a linked Table of Contents (ToC): click on any heading in the ToC to go directly to that task – this is a standard navigation feature in pdf files

If you only want a specific task and don’t want to view or download the model-specific files, then below the Constructors Manuals are all the individual tasks in the Constructors Manual, listed in the correct build sequence, all of which are small .pdf files of between 4 and 8 pages. Click on any task to view or download.

Model identification for the individual files: “J100” denotes J160 and J170, “J2400” denotes J230, J250, J430 and J450. “J2430” denotes J230 and J430, “J2450” denotes J250 and J450 and so on. “JALL” denotes all “J” series aircraft.

Regardless of which tasks you choose to view, we recommend that you start by reading the General Introduction before proceeding to the individual tasks. This contains important information and should be read thoroughly before and during your build.

Jabiru J160 Construction Manual
Jabiru J170 Construction Manual
Jabiru J230 Construction Manual
Jabiru J430 Construction Manual
Jabiru J250 Construction Manual
Jabiru J450 Construction Manual
Build Sequence for Kit Aircraft
General Introduction
Pre-Paint
Fuselage
Underbody penetrations_J2400
Fit ventral fin and trim horn_JALL
Prepare fuselage_J100
Prepare fuselage_J2400
Undercarriage
Undercarriage_Assemble main wheels_JALL
Undercarriage Assemble main gear/brakes J160
Undercarriage Assemble main gear/brakes J1702400
Undercarriage_Fit main gear J100
Undercarriage_Fit main gear_J2400
Firewall
Fit firewall_JALL
Firewall fittings_J100
Firewall fittings_J2400
Assemble and fit nose gear_J100
Assemble and fit nose gear_J2400
Fit engine and mount_J100
Fit engine and mount_J2400
Fit windscreen_JALL
Fit control cables and lines_J100
Fit control cables and lines_J2400
Empennage
Fit vertical tail fin J100
Fit vertical tail fin J2400
Fit elevator J160
Fit elevator_J170_2400
Fit horizontal stabiliser_J100
Fit horizontal stabiliser J2400
Fit Rudder J160
Fit Rudder J1702400
Engine
Fit propeller flange extension JALL
Fit ram air cooling ducts_J2400
Fit ram air cooling ducts_J100
Fit oil cooler J100
Fit oil cooler J2400
Fit cowling_J100
Fit cowling_J2400
Fit flap drive shaft mounts_JALL
Interior
Console - Pre-Fit Handbrake_JALL
Console - Pre-Fit Trim Control_JALL
Console - Fit Control Stick_JALL
Fit Rudder Pedal Mount Blocks_JALL
Fit aileron cable brackets J100
Fit aileron cable brackets J2400
Fuel System_J100
Fuel System_J2400
Fit seatbelt anchors_J100
Fit seatbelt anchors_J200
Fit seatbelt anchors_J400
Fit rear seat_J400
Pre-fit doors_J100
Pre-fit doors_J2400
Fit door gutters_J2400
Fit windows_JALL
Wheel Alignment_JALL
Pre-Fit wheel spats_JALL
Wings
General_JALL
Fit fuel tank filler body_J100_2430
Fit fuel tank filler body J2450
Prepare wing root J160
Prepare wing root J170
Prepare wing root J2430
Prepare wing root J2450
Cut aileron cable inspection opening_JALL
Fit quick drain sumps J160
Fit quick drain sumps J170 J2430
Fit quick drain sumps J2450
Mount flaps_J100
Mount flaps_J2430
Mount flaps J2450
Fit Wing tips_J160
Fit Wing tips_J170_2430
Fit Wing tips J2450
Fit Ailerons J1602400
Fit Ailerons J170
Fit pitot tube to strut JALL
Fit vibration damper to strut J1702400
Test Fit Wings JALL
Paint
Painting JALL
Post-Paint
Fuselage
General JALL
Fit Panel Mounted Throttle JALL
Assemble Instrument Panel JALL
Electrical Wiring Diagrams JALL
Fit Upholstery JALL
Install Electrical Wiring JALL
Interior
Fit console controls J160
Fit console controls J1702400
Fit rudder pedals J160
Fit rudder pedals J170
Fit rudder pedals J2400
Fit flap drive motor J100
Fit flap drive motor_J2400
Fit instrument panel housing JALL
Fit instrument panel JALL
Fit upholstery J100
Fit upholstery J200
Fit upholstery J400
Empennage
Fit rudder and elevator J160
Fit rudder and elevator J1702400
Fit doors J100
Fit doors J2400
Firewall Forward
Engine Control Cabling J100
Engine Control Cabling J2400
Fit propeller and spinner_JALL
Connect cabin heater JALL
Fit Wheel Spats JALL
Wings
Install Aileron Cables J160
Install Aileron Cables J2430
Install Aileron Cables J2450
Fit Stall Warning J100
Fit Stall Warning J2400
Prepare wings for fitting J160
Prepare wings for fitting J170
Prepare wings for fitting J2430
Prepare wings for fitting J2450
Fit Wings JALL
Connect ailerons JALL
Connect wing tanks J100
Connect wing tanks J2400
Fit flaps J100
Fit flaps J2400
Fit fairings J100
Fit fairings J2400
Testing
General JALL
Weight and Balance J100
Weight and Balance J2400
Rigging Check JALL
Calibrate Fuel Gauges JALL
Fit Registration Marks JALL
Final Inspection Checklist J160
_Final Inspection Checklist J1702400
Flight Testing JALL
Flight Testing Forms JALL
Troubleshooting VHF Noises JALL

 

Card Diagrams

Card Dwgs J160 170
Card Diagrams J160/170

Card Dwgs J160 170
Card Diagrams J230/430

Service Bulletins & Notices

All bulletins on this page can be searched by pressing Ctrl-F or ⌘-F, or alternatively select from one of the following categories:
Airframe Service Bulletins
Engine Service Bulletins

Notices

Click here for notice/letter regarding rotor arms.

CASA have released Airworthiness Bulletin AWB 27-001 Issue 3 regarding the inspection and replacement of certain stainless steel fittings used in aircraft control systems. Jabiru Aircraft do not use the exact fittings mentioned in this bulletin, however we use the same materials in a similar manner. The content of this bulletin is therefore applicable to Jabiru Aircraft and operators must comply with its requirements. Click here to access this bulletin.

RA-Aus Safety Bulletin "SB-002-15-08-2012-All-Aircraft-Control-Cables" has also been released on the same subject, however the official RA-Aus position is that the RA-Aus Bulletin is NOT applicable to Jabiru Aircraft.

The RA-Aus Bulletin has different compliance and implementation requirements to the CASA Bulletin.

Note that replacing primary control cables is a safety critical task. Failure to carry out the task correctly will result in unsafe condition. All work must be carried out by authorised personnel to current, approved data.

The latest revision of the Jabiru Aircarft Technical Manual - JTM001 -  contains details on correctly replacing cables and must be referred to for this task. operators must also be aware of the content of Jabiru Service Bulletin JSB027 - Control Cable Inspection (Kit Built Aircraft). Both of these documents are available for download from this website. 

LSA Owner/Operator Responsibilities

The following responsibilities for the owner/operator of a LSA listed are prescribed in the ASTM standard F2295:

 

  • Each owner/operator of a LSA shall read and comply with the maintenance and continued airworthiness information and instructions provided by the manufacturer.
  • Each owner/operator of a LSA shall be responsible for providing the manufacturer with current contact information where the manufacturer may send the owner/operator supplemental notification bulletins.
  • The owner/operator of a LSA shall be responsible for notifying the manufacturer of any safety of flight issue or significant service difficulty upon discovery.
  • The owner/operator of a LSA shall be responsible for complying with all manufacturer issued notices of corrective action and for complying with all applicable aviation authority regulations in regard to maintaining the airworthiness of the LSA.
  • An owner of a LSA 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 LSA shall be considered not in compliance with applicable ASTM standards and may be subject to regulatory action by the presiding aviation authority.

 

Click Here for Airworthiness, Liability and Warranty Document

 

Airframe Bulletins & Advisory Notices

JSL019-2 Rudder Cable End Inspection Dec 14 2015

JSB029-2 Jabiru J170 Handling Upgrade July 30 2015
Applicability: J170-C Aircraft up to S/No. 317 and J170 aircraft using original tail fin

JSB009-2 Alternate Propeller Mount System June 29 2015

Applicability: All Jabiru Wooden Propellers

JSL003-2 Jabiru Fuel Tank Sealant June 29 2015

Applicability: All Jabiru Aircraft

JSL017-1 Pattern Parts June 26 2015
Applicability:  All Jabiru Aircraft & Engines

JSB038-1 Jabiru Composite Propeller June 22 2015
Applicability: All Jabiru Composite Props

JSB037-1 Wing Attachment Bolts March 20 2015
Applicability: Jabiru Aircraft with over 2000 Airframe Hours

JSB019-2 Control Surface Clearance Nov 24, 2010

Applicability: All Jabiru Aircraft

JSB030-2 LSA Category Weight Limitations - South Africa May 25 2011
Applicability: Jabiru J200-299 Aircraft Family operating under LSA category in South Africa only
JSB028-1 4 Seat / 2 Seat Conversion (Kit Built Models) Oct 29, 2010
Applicability: Kit/Amateur Built Jabiru Models J200 J400 J230 J430 J450 J250

JSB027-1 Control Cable Clamp Inspection (Kit Models) July 9, 2009

Applicability: All Kit Built Jabiru Aircraft

JSB017-4 Digital Instrument (EFIS & EMS) Maintenance May 5, 2009
Applicability: All Jabiru Factory Built Airrcaft equipped with Dynon EFIS and/or EMS instruments

JSB026-1 Adjustable Rudder Pedal J160 170 Jan 15, 2009

Applicability: Jabiru J160-C and J170-C Factory Built Models

JSB025-2 Undercarriage Bolt Life May 7, 2009

Applicability: All models of Jabiru Aircraft. Includes both kit built and factory built models

JSB023-1 Configuration Update 2 J160-C Jan 14, 2009

Applicability: Jabiru J160-C Aircraft

JSB024-1 Fuel Line Routing Jan 9, 2009

Applicability: All Jabiru models equipped with wing tanks both factory built and kit built

JSB020-1 Bell Crank Mar 4, 2008

Applicability: J160-C, J170-C, J230-C and J230-D factory built models

JSB011-1 Fit Lower Seatbelt Attachments Aug 16, 2005

Applicability: Jabiru LSA, SP, UL & Early J160 models (including variants such as Calypso)

JSB008-1 Main Undercarriage bolts Mar 31, 2005

Applicability: Jabiru J400 Family (J400, J430, J450)

JSB007-1 Stub Axle Replacement  Nov 29, 2004

Applicability: All Jabiru Aircraft

JSL001-1 Header Tank Upgrade  Nov 22, 2004

Applicability: Jabiru Aircraft with wing tanks

JSB006-1¼” Nose Leg Pivot Bolt Oct 21, 2004

Applicability: Early Jabiru Aircraft Models with 1/4" nose leg pivot bolt

JSB003-1 J Series Door Hinge Oct 14, 2004

Applicability: J400, J200, J430, J230, J450, J250 models

JSB002-1 J400 Elevator  Drive Arm Oct 11, 2004  
ONLY APPLIES TO J400's flying under our PFA certification package UK

JSBA4 Elevator Travels On All Aircraft Dec 18,2001

JSBA3 Fuel System Cleaning Jan 25, 2000
Sensenich Propeller Service Bulletin 10-07-21 (Composite Blade Only -Experimental)

 

Engine Service Bulletins & Advisory Notices


JSB040-1 Jabiru Mechanical Fuel Pump September 16 2016

Applicability: All Jabiru Engines

JSB012-3 Jabiru Engine Flywheel Attachment  June 30 2016
Applicability: All Jabiru Engines
JSL014-4 Jabiru Cylinder Head Inspection July 1 2016
Applicability: All Jabiru Engines
JSL018-1 Oil Cooler Hose Oct 1 2015
Applicability: All Jabiru Engines
JSL007-6 Alcohol Lead Compression Ratio Fuel Guidance Aug 5 2015
Applicability: All Jabiru Engines & Aircraft
JSB031-3 Engine Through Bolt Replacement and Upgrade Jan 15 2015
Applicability: Jabiru 2200 and 3300 Engines used in FLIGHT TRAINING OPERATIONS ONLY
JSL015-1 2200 Engine Distributor & Rotor Dec 15 2014
Applicability: Jabiru 2200 Engines S/No. 22A3574 - 22A3684 (includes 22B284, 22B286, 22B306, 22B318) & 2200 distributor & rotor parts supplied 21 Feb 2012 - 18 Dec 2013
JSL010-1 Service Time Intervals November 21 2014
Applicability: All Jabiru Engines
JSB018-3 Jabiru Engine Tuning October 15 2014
Applicability: All Jabiru Engines
JSB022-2 Propeller Flange Attachment June 20 2014
Applicability: All Jabiru Engines
JSL009-1 Starter Solenoid June 5 2013
Applicability: Accessory Kits sent with engines and spares invoiced Oct 2012 to May 2013
JSL008-1 Valve Spring Washer Adverse Wear Dec 21 2012
Applicability: All Jabiru Engines
JSB033-1 Piston Circlips Aug 17, 2012
Applicability: Specific Serial Numbers of 2200 and 3300 engines. See bulletin for applicable serial numbers
JSB014-2 Propeller Installation Maintenance June 9 2011
Applicability: All Jabiru Engines
JSB021-1 Configuration Update 1 J160-C Jan 14, 2009
Applicability: Jabiru J160-C Aircraft
JSL005-1 Starter Motor Earth Cable September 1, 2008
Applicablility: All Jabiru Aircraft
Dipstick Settings & Comparisons April 4, 2008
Applicability: 2200 and 3300 Engines
JSB010-3 Statement of Compliance to ASTM LSA Feb 20, 2008
Applicability: Engine Serial numbers 22A1845 and above, 22B001 and above, 22C001 and above, 33A722 and above, 33L722 and above
JSL004-1 Engine Cooling J230 Jan 29, 2008
Applicability: J230 Aircraft serial number range 292 to 578
JSL002-3 Engine Economy Tuning Cancellation of Service Bulletin Letter Oct 5, 2007
Applicablity: Cancelled. JSB018-1 replaces this letter
JSB016-1 Engine Cooling Apr 19, 2007
Applicability: All J160 and J170 models
JSB013-1 Engine Rocker Chamber Vent Aug 8, 2006
Applicability: 2200 Engines Serial Numbers 22A2068 - 22A2439 and 22B002 - 22B028
JSB004-3 Jabiru_Engine Oil Pump 31 Mar, 2005
Applicability: All Jabiru engines fitted with oil coolers
JSB005-1 Jabiru 6 Cylinder Engine Muffler Oct 10, 2004"
Applicability: 3300 engines witted with a Jabiru Muffler
JSB001-1 Revised Jabiru Engine TBO's May 11, 2004
Applicablity: 2200 and 3300 engines
Oil Cooler Mounting Instructions Aug 15, 2001
Applicability: Jabiru OilCoolers
JSBA3 Fuel Systems Cleaning Jan 25, 2000

Spare Parts

Please download this Spare Parts Order Form (Word Document), save it and then email the file as an attachment to This email address is being protected from spambots. You need JavaScript enabled to view it. or print and fax it to (07) 4155 2669.