Manuals

Engine Maintenance Manuals

Engine Overhaul Manuals

Cold Start Checklist

Maintenance Persons Information

Trouble Shooting 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

Airframe Constructors Manual


List of Avionics & Instruments Repair/Calibration Service Centres in Australia

 

Click here for Owners/Operators Responsiblilites for Continued Operational Safety Monitoring

 

Engine Maintenance Manuals

Engine Maintenance Manual (Revision 3,  May 2014)
2200C Instruction and Maintenance Manual (Revision 10, April 2011)
J5100 Engine Maintenance Manual (Revision 3, June 2010)

 

Engine Overhaul Manuals

2200 / 3300 Overhaul Manual (Revision 6, June 2014) CASA Approval Pending
Overhaul Manual Work Books

 

 

 

Cold Start Checklist

Cold Start Checklist

 

Cold Start Installation Instructions

 

Maintenance Persons Information

Summary of Significant Engine Changes

 

Click Here for Procedure for Cylinder Head Modification for CHT Sensor Installation

 

Click Here for Procedure for Upgrading 12 Pole Alternator

 

Trouble Shooting Strobe Systems

 Trouble Shooting Strobe Systems

 

Engine Installation Manuals

J2200 Engine Installation Manual (Revision 7 January 2014)
J3300 Engine Installation Manual (Revision 5 January 2014)
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 Solid Lifter Engine
J5100 Solid Lifter Engine

 

 

 

Propeller Manuals

4 Cylinder Engine Propeller Technical Manual Issue 4 12th May 2014

(see J230 Aircraft Technical Manual for 6 cylinder engine propeller manual)

2200 and 3300 Jabiru Scimitar Propeller Manual  Issue 4 12th May 2014

 

Aircraft Technical Manuals

J120, J160/170, J230 Aircraft Technical Manual  (Issue 4, 12th May 2014) -

CASA Approved for J160C

 

 

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

 

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

 

 

Cards Diagrams 

_J230 & J430
_J160 & J170