RV 12is MM R3.8

Rev: 3.
8 Van’s Aircraft Date: 12/12/22
VAD-10005
MAINTENANCE MANUAL
Aircraft Serial Number: ____________________
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Rev: 3.8 Van’s Aircraft Date: 12/12/22
THIS PAGE INTENTIONALLY LEFT BLANK
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REVISION SUMMARY
Whenever revisions are issued, they must be inserted in the appropriate place in
the manual. A black vertical line along the left margin of the page will identify
revised text and illustrations. Changes in spelling, punctuation and formatting
will not be marked.
To verify the latest revision of the Maintenance Manual (MM) compare the rev.
level found on the cover page with the latest revision posted on the RV-12
Service Information page of the Van’s Aircraft web site.
Rev Page Change Date

0 None Initial Release 05/03/18
1 Multiple Publication 10/22/18
3-9 Added exhaust ball joint lubrication inspection item
4-2 Deleted note re. use of Cherry Max CR rivets
2 14-2 Muffler Assembly Part Number is “EX-00030”, was “Muffler Assembly” 11/15/18
17-3 Added note re. use of Cherry Max CR rivets
18-3,5 Added “Next Due” column to Service Schedule Checklist
3 1-21 Revised Installed Equip. List for G3X 6/4/19
1-21,22 INSTALLED EQUIPMENT LIST, updated the Skyview Weight and Arm values
3-8 FIREWALL FORWARD, removed cotter pins as inspection item
FWALL FWD, added “Check exhaust sys. ball joints for proper anti-seize
3-9
lube”
4-2 Moved “Cherry Max CR series rivet …” note to Page 17-3
3.1 9/30/19
14-2 “EX-00030” in the Components table was “Muffler Assembly”
16-3 Added QR code link to how to video to access ROTAX 912iS fault info in EFIS
17-3 Revised “rivets” section.
18-3 Added: ELT Self-Test, Insp. bat. Life for RC Panel & Audio Alert Ind.
18-15 In the INSPECTION CHECKLIST add the “Self-Test”
1-15 Added 220-240 in-lbs for AN5 with Nord -Lock washers on 3 blade prop
3.2 11-1 Added three blade propeller Figure 12/13/19
11-2 Added two rows to components table for 3 blade prop & spinner cone
1-21 INSTALLED EQUIPMENT LIST, updated GTX 35R weight value
13-15 Added references to FLF-00024 seal washers
3.3 05/14/20
14-2 COMPONENTS and SUPPLIES, added Exhaust M8-WS12 Lock Nuts
14-3 Added M8-12WS Nuts to REPLACEABLE line
Replaced GMC 307 with GMC 507. Replaced installed weight from 0.62 lbs to
1-21
0.68 lbs.
Replaced GTN 650 with GTN 650Xi. Replaced installed weight from 7.0 lbs to
1-22
5.5 lbs.
3.4 6-2 Replaced GMC 307 with GMC 507 09/08/20
9-3 Replaced GMC 307 with GMC 507
Added note to dynamically balance propeller if vibrations are noticed or prop
11-4
pitch has been changed
12-10 Replaced SPRING-00002 with SPRING-00002-L/R-1
Removed statement on rotating prop if engine roughness was noted as it is
3.5 11-4 not applicable to the Rotax installation; Rephrased dynamic propeller balance 10/30/20
instructions
All Added “Printed copies are uncontrolled.” to footer.
3.6 14-2 Updated part numbers in “COMPONENTS” Table 12/03/20
14-3,4 Added slip joint references to lubrication steps.
All Added “VAD-10005” to footer
3-16, 5-13, 9-
Added clarification for FLF-00015 identification and testing
2, 18-3, 25
3.7 02/26/21
9-4 Added FLF-00015-1 to AOA system components
18-3, 11 Added inspection schedule for checking control system cable tension
18-5 Updated Fuel Tank Finger Strainer inspection to “One time per year”
i, All Added VAD-10005 to title. Added “Van’s Aircraft” to all pages.
5-3 C-01205-3 was C-01205-2
3.8 12/12/22
1-21 GA 26X was GA 26C
18-3 Added line service item “Exhaust flat springs”
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OWNER/OPERATOR RESPONSIBILITIES
For continued airworthiness of an RV-12iS aircraft, the owner/operator must comply

with the following requirements as dictated in ASTM F 2295 Section 5.
Each owner/operator of an RV-12iS shall read and comply with the

Maintenance Manual and continued airworthiness information and
instructions provided by Van's Aircraft Inc.
Each owner/operator of an RV-12iS shall provide Van's Aircraft Inc. with up to

date contact information so that Van's Aircraft may send the owner/operator
supplemental notification bulletins. Contact Van's Aircraft Inc. using the
following information:
Van's Aircraft, Inc.

14401 Keil Road, NE
Aurora, OR 97002 USA
Phone: 503.678.6545
Fax: 503.678.6560
Website: www.vansaircraft.com
email: [email protected]
The owner/operator of an RV-12iS shall notify Van's Aircraft Inc. of any safety
of flight issue or significant service difficulty upon discovery using the
Feedback Form provided in the Maintenance Manual.
The owner/operator of an RV-12iS shall comply with all Van's Aircraft Inc.
issued notices of corrective action and comply with all applicable aviation
authority regulations regarding maintaining the airworthiness of the LSA.
Notices of corrective action are published on the Van’s Aircraft web site RV-
12iS Service Information Page.
An owner of an RV-12iS shall ensure that any needed corrective action be

completed as specified in a notice.
Should an owner/operator not comply with any mandatory service requirement

the RV-12iS shall be considered not in compliance with applicable ASTM
standards and may be subject to regulatory action by the presiding aviation
authority.
The owner/operator may submit written comments and questions regarding

any mandatory Notice to the organization who issued the Notice.
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TABLE OF CONTENTS
CHAPTER 1- GENERAL
INTRODUCTION ............................................................................................................ 1-1

Purpose.................................................................................................................. 1-1
Summary................................................................................................................ 1-1
Scope ..................................................................................................................... 1-2
Replacement Parts................................................................................................. 1-3
Method ................................................................................................................... 1-3
APPLICABLE THROUGHOUT ........................................................................................... 1-4
General Safety ....................................................................................................... 1-4
Safety of Flight Reporting Procedure ..................................................................... 1-5
Helpful Terminology ............................................................................................... 1-5
Abbreviations ......................................................................................................... 1-6
Units ....................................................................................................................... 1-7
TOOLS AND EXPENDABLES ........................................................................................... 1-8
ENGINE ..................................................................................................................... 1-12
LUBRICATIONS AND CAPACITIES .................................................................................. 1-13
Engine Oil............................................................................................................. 1-13
Brake Fluid ........................................................................................................... 1-13
Engine Coolant..................................................................................................... 1-14
Fuel ...................................................................................................................... 1-14
Tire Pressures ...................................................................................................... 1-14
Torque Values ...................................................................................................... 1-15
GENERAL PROCEDURES ............................................................................................. 1-16
Lifting & Supporting the fuselage ......................................................................... 1-16
WEIGHT AND BALANCE ............................................................................................... 1-18
EQUIPMENT LIST ....................................................................................................... 1-21
CHAPTER 2- SERVICE SCHEDULE .......................................................................... 2-1
CHAPTER 3- INSPECTION......................................................................................... 3-1
OVERSTRESS .............................................................................................................. 3-1

OVERVIEW .................................................................................................................. 3-2
INSPECTION DESCRIPTION ............................................................................................ 3-3
Pre-inspection / Post-inspection ............................................................................. 3-3
Cockpit ................................................................................................................... 3-5
Radio...................................................................................................................... 3-6
Optional Equipment................................................................................................ 3-7
Emergency Locator Transmitter ............................................................................. 3-7
Propeller................................................................................................................. 3-7
Engine .................................................................................................................... 3-8
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Firewall Forward..................................................................................................... 3-8

Fuselage .............................................................................................................. 3-12
Landing Gear ....................................................................................................... 3-13
Wing / Center Section/AOA ................................................................................. 3-14
Empennage.......................................................................................................... 3-10
Angle-Of-Attack System ....................................................................................... 3-16
Paperwork ............................................................................................................ 3-17
CHAPTER 4 - STRUCTURAL REPAIRS .................................................................... 4-1
OVERVIEW .................................................................................................................. 4-1

MINIMUM CERTIFICATION .............................................................................................. 4-2
CHAPTER 5 - STRUCTURES ..................................................................................... 5-1
OVERVIEW .................................................................................................................. 5-2

FUSELAGE................................................................................................................... 5-2
WING AND FLAPERON .................................................................................................. 5-4
EMPENNAGE................................................................................................................ 5-6
LANDING GEAR ............................................................................................................ 5-8
FAIRINGS - WHEEL AND GEAR LEG................................................................................ 5-10
SERVICE ................................................................................................................... 5-12
CHAPTER 6 - FLIGHT CONTROLS............................................................................ 6-1
OVERVIEW .................................................................................................................. 6-2

SERVICE ..................................................................................................................... 6-3
CHAPTER 7 - BRAKE SYSTEM ................................................................................. 7-1
OVERVIEW .................................................................................................................. 7-2

SERVICE ..................................................................................................................... 7-2
CHAPTER 8 - ELECTRICAL SYSTEM ....................................................................... 8-1
OVERVIEW .................................................................................................................. 8-2

SERVICE ..................................................................................................................... 8-4
CHAPTER 9 - INSTRUMENTS & AVIONICS .............................................................. 9-1
OVERVIEW .................................................................................................................. 9-2

PITOT & STATIC ........................................................................................................... 9-3
SERVICE ..................................................................................................................... 9-4
CHAPTER 10 - UTILITY SYSTEMS .......................................................................... 10-1
OVERVIEW ................................................................................................................ 10-2

HEAT ........................................................................................................................ 10-2
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VENTILATION ............................................................................................................. 10-3

SERVICE ................................................................................................................... 10-4
CHAPTER 11 - PROPELLER.................................................................................... 11-1
OVERVIEW ................................................................................................................ 11-2

SERVICE ................................................................................................................... 11-2
Prop & Hub.......................................................................................................... 11-3
CHAPTER 12 - FIREWALL FORWARD.................................................................... 12-1
OVERVIEW ................................................................................................................ 12-2

Engine ................................................................................................................. 12-3
SERVICE ................................................................................................................... 12-4
CHAPTER 13 - FUEL SYSTEM................................................................................. 13-1
OVERVIEW ................................................................................................................ 13-2

Fuel System Schematics..................................................................................... 13-4
SERVICE ................................................................................................................... 13-6
CHAPTER 14 - EXHAUST SYSTEM ......................................................................... 14-1
OVERVIEW ................................................................................................................ 14-2

SERVICE ................................................................................................................... 14-4
CHAPTER 15 - PAINTING AND COATINGS ............................................................ 15-1
OVERVIEW ................................................................................................................ 15-2

SERVICE ................................................................................................................... 15-3
CHAPTER 16 - TROUBLESHOOTING ..................................................................... 16-1
CHAPTER 17 - FEEDBACK & REPLACEMENT PARTS ......................................... 17-1
REPORTING METHODS ............................................................................................... 17-1

REPLACEMENT PARTS ................................................................................................ 17-2
SUBSTITUTE PARTS ................................................................................................... 17-2
CHAPTER 18 - SUPPLEMENT ................................................................................. 18-1
SERVICE SCHEDULE................................................................................................... 18-3

INSPECTION CHECKLIST ............................................................................................. 18-7
3-VIEW ................................................................................................................... 18-31
FEEDBACK FORM ..................................................................................................... 18-33
CHAPTER 19 - GLOSSARY...................................................................................... 19-1
CHAPTER 20 - INDEX............................................................................................... 20-1
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NOTE: Pages 1-21/22 and 1-23/24 correspond to a particular EFIS installation.

Please remove all pages that do not correspond to your EFIS.
Specific EFIS type is noted next to the page number.
APPENDIX ‘A’ - KIT ASSEMBLY INSTRUCTIONS (KAI) (NOT PART OF, BUT AN
APPENDIX TO THIS MANUAL)
Addendum Documents list (Notification, Service Bulletin, etc.)

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

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

REPLACEMENT PARTS
The RV-12iS KAI is the primary reference for replacement part information.
Section Four in the KAI is a directory of all part numbers with reference information of
where to find it within the main KAI manual. The documentation produced by third party
parts manufacturers (listed above) should be used as the primary reference for part
information for those components.
METHOD
The RV-12iS can be equipped with either a Rotax 912ULS or a Rotax 912iS
engine. For the purpose of this manual, when entire sections, or specific maintenance
or inspection tasks are specific to just one of the aircraft versions, a [ULS] or [iS]
notation will be used.
The pages throughout this maintenance manual are numbered at the bottom with
the chapter number followed by a dash and the page number of the applicable chapter.
There are many cross-references in this manual. Cross-references within this manual
are made using the page numbers, unless otherwise specified. Following is an example
of a typical cross-reference to additional information within this manual. Example: When
there is additional information that is related to this sentence the cross-reference to that
page will be in parenthesis following the period. (1-2)
Chapter 1 will introduce general information that is helpful for using this manual.
General information includes manual introduction, general safety information,
notification methods, abbreviations, collective tool list, list of expendables, lubrication
and capacities and general procedures.
Chapter 2 introduces the service schedule checklist.
Chapter 3 provides an explanation of the annual/100 hour inspection checklist
including illustrations that clarify some checkpoints of the aircraft. Read Chapter 1-3
prior to performing the inspection, and use it as a reference during the inspection.
Chapter 4 and following begin with an illustration of the subject discussed, an
‘Overview’ of the chapter content and a list of ‘Components’. The 'Service' section,
where applicable, begins with a table of ‘Supplies’, which includes; ‘Tools’, ‘Expendable’
and ‘Replaceable’ parts. The service section provides instructions for ‘General’ removal,
replacement and installation that are acceptable for the owner or operator to perform.
The service section also includes instructions for ‘Service Schedule Procedures’ which
correspond to the items on the 'Service Schedule Checklist'. Each service section task
includes a table that summarizes the properties of the task.
The task summary table lists the Tools, Expendable, and Replaceable items that
are task specific. Only tools specific to the immediate task will be listed. In cases that
another task must be done to complete the immediate task, the tools needed for the
other task will be given in the instructions that correspond to that task. Some
recommended tools will require other tools to be effective; for example: sockets will
require a ratchet; drill bits will require a drill. Unless otherwise specified the driving tool
is implied rather than listed. The table also includes the ‘Service Rating’ applicable to
the task, the ‘Minimum Certification’ required to perform the task legally, and ‘Additional

References’ that may be helpful or necessary to complete the task. Each hardware item
to be removed in the service instructions will be followed by the quantity (if greater than
one) in parenthesis. For example, an instruction step that requires the removal of one
bolt, six washers and two nuts will appear as follows: 1. Remove the bolt, washers (6),
and nuts (2).
Chapter 16 offers direction for solving potential problems that may puzzle the
owner of any aircraft.
Chapter 17 provides instructions for reporting the discovery of anomalies that
could compromise the airworthiness of the aircraft as dictated in ASTM F 2295 Section
5.
Chapter 18 includes the inspection checklist, service schedule checklist and
other helpful documents.
APPLICABLE THROUGHOUT
GENERAL SAFETY
Safety must be considered the first priority when performing maintenance or
service on an aircraft or part. The content in this manual is only for use in a safe work
environment with all necessary safety equipment readily available and in use when
applicable.
Maintenance or repair classified in this manual as owner and SPC, and in 14
CFR, FAR 43 Appendix 'A' can be done by an RV-12iS owner or operator that
possesses a Sport Pilot certificate or higher.
An LSA Repairman certificate with a Maintenance rating or an FAA issued
A&P certificate are the minimum level of certification to perform line maintenance
or repairs and the annual condition inspection on an S-LSA RV-12iS.
AN E-LSA RV-12iS has no level of certification requirement for maintenance or
repairs, so none is given. The person completing an annual condition inspection on an
E-LSA RV-12iS is required to possess a Repairman / Inspection certificate (airplane).
Prior to performing maintenance or repair always disconnect the negative (-)
battery cable from the battery.
The strength of an airframe designed using semi-monocoque construction relies
on both the skins and the skeleton for complete structural strength. If a skin has been
damaged, the underlying structure may also have been damaged. Carefully inspect any
damage to assess the extent of the damage. If the damage is localized to just outer
skins, they can be removed and replaced. If inspection indicates that the substructure is
also damaged the damaged parts must be replaced or the aircraft manufacturer must
be consulted for further assessment.
Every time hardware is removed it must be checked for signs of wear or fatigue.
Inspect the head, shank, and threads of bolts, and the edges and threads of nuts.
Safety wire, cotter pins, lock washers and similar hardware are only reliable for one
term of service and should be replaced on removal with the exception of the Nordloc®
washers used on the propeller bolts (refer to propeller documentation). It is permissible

to reuse nylock and all steel style self-locking nuts if it is determined that the self-locking
feature has not been degraded. Always replace questionable hardware.
Operation in Extreme Conditions: Exposure to extreme climatic conditions,
including but not limited to dust, salt, debris, bugs, will warrant more frequent
inspections of air filters, coolant radiator, and oil cooler as defined in the Rotax
maintenance manual. Frequent exposure to extreme conditions or altitudes may
demand additional equipment or maintenance. Contact an authorized Rotax distributor
for consultation.
SAFETY OF FLIGHT REPORTING PROCEDURE

To maintain the highest level of safety and as dictated in ASTM F 2295 Section
5, the FAA requires and Van’s Aircraft Inc. requests, notification of any safety of flight
issue, or service or maintenance difficulties that could compromise the airworthiness of
the RV-12iS aircraft. A feedback form is provided in the Supplement section of this
manual. Refer to Chapter 17 for a description of a valuable report and the
different reporting methods available.
HELPFUL TERMINOLOGY
▲ WARNING: INDICATES AN ACTION NECESSARY TO PREVENT INJURY OR DEATH.
■ CAUTION: INDICATES AN ACTION NECESSARY TO PREVENT DAMAGE TO PARTS OR

PROPERTY.
● NOTE: PROVIDES VALUABLE ADDITIONAL INFORMATION.
The Glossary provides definitions to many of the terms used throughout this manual.

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

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

TOOLS AND EXPENDABLES

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

ILLUSTRATIONS ARE ONLY EXAMPLES OF WHAT A TOOL MAY LOOK LIKE.

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

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

■ CAUTION: REPLACEMENT PARTS MUST BE OF THE EQUIVALENT SIZE, TYPE AND

RATING AS THE ORIGINAL PARTS FROM THE MANUFACTURER.
EXPENDABLE
PARTS PART NUMBER
Oil filter Rotax 825 701 (or equivalent)
Fuel Filter [iS] Rotax 874 060
Copper crush ring (for oil tank drain Rotax 250010
plug)
Gas-6 O-ring gasket [ULS] GASKET GAS-345
Tire U-5:00X5 Tire (any aircraft grade 5:00X5, 4 or 6
ply tire is acceptable.
Inner tube U 5:00X5-6IT (any aircraft grade 5:00X5-6 inner
tube is acceptable)
Brake shoe linings M66-106 (or equivalent)
Fuses ATO/ATC ¼s style 1, 2, 3, 5, 7.5, 30 Amp
rating. All fuse values of 3 amp and higher are
required to have LED “blown fuse” indicators.
LUBRICANTS RECOMMENDATION OR EQUIVALENT
Engine oil As specified in latest Rotax documentation
Spray lubricant LPS2, Tri-Flow, or similar
Dry lubricant (candle wax, etc.) TOOL BOELUBE PASTE
Wheel bearing grease Aeroshell 22 or equivalent
Pipe Thread-Sealant Loctite 567 or equivalent
Anti-seize compound, High temp Loctite Anti-Seize or equivalent (High Temp.
Nickel based)
Silicone Grease Down Corning #4 or equivalent
Hydraulic fluid MIL-PRF-83282 (preferred) or MIL-H-5606A
Air filter cleaner and oil EA K&N 99-5050 KIT
MISCELLANEOUS RECOMMENDATION OR EQUIVALENT
Engine coolant 1:1 Water/Ethylene Glycol (refer to Rotax
engine documentation)
Safety wire WIRE, SAFETY .032
Fuel tank sealant MC-236-B1/2 or MC-236-B2
Plexus Cleaner/Polish CA CANOPY CLEANER
Cotter pins MS24665-xyz
Plastic tie wraps Non-specific
Wire terminals Male & Female spade, splice, and ring
Primer Any protective primer suitable for use on
aluminum and/or steel as appropriate
Decorative touch-up paint From paint process
Thread locking compound Loctite 243 or Equiv.

ENGINE DESCRIPTION
The LSA covered by this manual may be equipped with either a Rotax 912ULS
or a Rotax 912iS power plant. Both are an over-head valve four-stroke, horizontally
opposed four-cylinder. The cylinder heads are liquid cooled. The cylinder barrels are air-
cooled.
The 912 ULS has dual constant depression carburetors to regulate the air/fuel
mixture, and a dual breaker-less, capacitor discharge ignition system to provide the
electrical energy to the spark plugs.
The 912iS has a fully redundant electronic engine management system (EMS)
controlling dual electronic ignition for the sparkplugs, dual electronic fuel injection, and
dual power generation/distribution.
For engine maintenance and inspection requirements and procedures, refer to
the Rotax Engine Type 912ULS or 912iS Series Line Maintenance and Heavy
Maintenance manuals.
ENGINE SPECIFICATIONS
SUMMARY
Make Rotax 912 ULS
Displacement 1352 cc
Ignition Ducati Double CDI
Carburetor Bing
Rated Horsepower 100 Hp @ 5800 RPM
● NOTE: THE ENGINE SPECIFICATION INFORMATION IS REFERENCED FROM THE
ROTAX 912 SERIES, OPERATOR’S MANUAL, OM EDITION 4, REV.0.
SUMMARY
Make Rotax 912 iS Sport
Displacement 1352 cc
Ignition Computer controlled
electronic
Fuel Injection Computer controlled
electronic
Rated Horsepower 100 Hp @ 5800 RPM
● NOTE: THE ENGINE SPECIFICATION INFORMATION IS REFERENCED FROM THE
ROTAX 912 SERIES, OPERATOR’S MANUAL, OM EDITION 1,REV.3.

LUBRICATION AND CAPACITIES
ENGINE OIL
■ CAUTION: ONLY USE API CLASS 'SG'
OR HIGHER.
■ CAUTION: DO NOT USE OILS WITH
FRICTION MODIFIER ADDITIVES.
■ CAUTION: DO NOT USE OILS FOR

“CONVENTIONAL” AIRCRAFT ENGINES.
■ CAUTION: DO NOT USE OILS
DESIGNED FOR DIESEL ENGINES.
i Capacity: 3 liter (3.2 US qts)

i The type of oil to use will be based on the
type of fuel used.
i Refer to the Rotax operator’s manual and
Service Instruction SI 912-016 for the
appropriate engine model, to determine
which oil type is appropriate for your
operating temperatures and the fuel being
used.
BRAKE FLUID
▲ WARNING: NEVER USE AUTOMOTIVE BRAKE FLUID.
Use MIL-H- 5606A or MIL-PRF-83282 (preferred)

Brake fluid draining, flushing, and replacing instructions Page 7-5.
CAPACITY:
15.4 fl. oz. (US) (.455 liters)

ENGINE COOLANT
SUITABLE COOLANTS
COOLANT MIX:
x 50% ethylene glycol concentrate with anticorrosion additives designed for
aluminum without sulfates or phosphates.
x 50% distilled or de-mineralized water.
See the latest version of the Rotax Operators Manual and Service Instruction SI 912-
016 for further information on coolant types and limitations.
CAPACITY:
0.7 gallon (US) (2.6 liters)
Fully fill the expansion tank, and fill the over flow bottle midway between the ‘min’ and
‘max’ marks.
MINIMUM:
Fluid level at or above the minimum line on the overflow bottle when engine is cold.
FUEL
SUITABLE FUEL
91 AKI (premium unleaded automotive)
100 LL Aviation Fuel
See the latest version of the Rotax Operators Manual and Service Instruction SI 912-
016 to determine other approved fuel types, limitations and maintenance
considerations.
CAPACITY:
20.2 US Gallons (76.5 liters)
TIRE PRESSURES
Tire psi psi max bar bar max kpa kpa max
Nose 22 23 1.517 1.586 152 159
Main 25 28 1.724 1.931 172 193

TORQUE VALUES
Torque applied is for the size of the bolt shank not the wrench size. On smaller bolts
use a torque wrench calibrated in inch pounds, not foot pounds.
When tightening fasteners installed with self-locking nuts or nutplates, the chart
values must be modified. The friction drag torque must be determined and then
added to the standard torque from the table. Due to the friction of the locking device
noticeable torque, known as friction-drag (or prevailing) torque, is required just to turn
the nut on the bolt threads and does nothing to actually tighten the parts together and
stretch the bolt (clamp load). Run the nut down to where it nearly contacts the washer or
bearing surface (at least one thread should protrude from the nut) then measure the
friction drag torque required just to turn the nut. Add this friction drag torque to the
standard torque (examples of standard torque values appear in the table below) to get
the final (or total) torque. The final torque is the amount of torque to be applied to the
joint. A snap-over type torque wrench should be set to the final torque.
For the two blade prop: refer to the latest version of the Sensenich INSTALLATION
AND OPERATION MANUAL FOR JABIRU AND ROTAX ENGINES DOC#: 2A0.
For the three blade prop: refer to the latest version of the Sensenich INSTALLATION
AND OPERATION MANUAL FOR ROTAX ENGINES DOC#: 3Y0R5.
Refer to the latest version of the Rotax Illustrated Parts Catalog for torque values and
installation details regarding the 912ULS engine, and the line and Heavy Maintenance
Manuals for the 912iS.
AN Bolt size - Standard nuts

Bolt Threads per inch AN310, AN315, MS20365
size
Inch pounds Foot Pounds
AN3 #10-32 20-25 1.6-2.0
AN4 1/4-20 50-70 4.2-5.8
AN5 5/16-24 (with plain washers) 100-140 8.3-11.6
5/16-24 (with NORD LOCK washers) 220-240 18.3-20
AN6 3/8-24 160-190 13.3-15.8
AN7 7/16-20 450-500 37.5-41.7
AN8 1/2-20 480-690 40-57.5
AN9 9/16-18 800-1000 66.6-83.3
AN10 5/8-18 1100-1500 91.6-125
(Portions of this information has been adapted from AC 43. 13)

GENERAL PROCEDURES
TIRE REMOVAL
WING REMOVAL REFER TO 5-1
CANOPY REMOVAL
COWL REMOVAL
REFER TO 12-1
OIL LEVEL CHECK
FUEL SYSTEM DRAINING
REFER TO 13-1
FUEL TANK REMOVAL
LIFTING & SUPPORTING THE FUSELAGE

▲ WARNING: USE STURDY SUPPORT STANDS THAT ARE EACH CAPABLE OF
SUPPORTING AT LEAST 500 POUNDS.
■ CAUTION: AVOID CONTACTING ANTENNA, FAIRINGS OR OTHER ACCESSORIES WHILE
PLACING THE SUPPORT STANDS UNDER THE AIRCRAFT.
■ CAUTION: REMOVE OR ATTACH THE WINGS PRIOR TO LIFTING AND SUPPORTING THE
AIRCRAFT.
When the aircraft is lifted, whether or not a jack is used, the method of support is
the same. Obtain two sturdy, padded stands each capable of supporting at least 500
pounds. The padded contacting surface must be at least 1 1/2 inches wide. Two layers
of 3/8 inch carpet are recommended. Both stands need to be about 30 inches long and
25 inches high.

LIFTING WITH A JACK

■ CAUTION: USE APPROPRIATE JACK LOCATING FIXTURES TO ENSURE A STABLE
JACKING SURFACE.
■ CAUTION: INSTALL A JACKPOINT WHEN LIFTING AT THE WING TIE-DOWN LOCATION.
1. Place a jack as necessary to lift at the lower end of the nose gear-leg.
2. Lift the front of the aircraft enough to position a stand along the lateral rivet pattern,
centered directly between the boarding steps.
3. Remove the jack.
4. Place the jack as necessary to lift on the tail tie-down.
5. Lift the tail of the aircraft enough to position a stand along the lateral rivet pattern
centered directly beneath the rear wing-spar receptacles.
6. Remove the jack.
7. Test stability of the aircraft. Grab the tail tie-down and test for horizontal and vertical
stability. Stabilize as necessary.
LIFTING WITHOUT A JACK
Figure 3: Lifting and supporting

● NOTE: STEPS 1 THROUGH 5 CORRESPOND TO THE NUMBERS IN FIGURE 3.
1. Raise the nose of the aircraft by lowering the tail.
2. Place a 25 inch tall stand along the lateral rivet pattern, centered directly between
the boarding steps.
3. Lift the tail of the aircraft.
4. Place another 25 inch stand along the lateral rivet pattern centered directly beneath
the rear wing-spar receptacles.
5. Check for horizontal and vertical stability. Stabilize as necessary.

WEIGHT AND BALANCE

It is the pilot’s responsibility to insure that the aircraft is loaded properly and
within the weight and balance limitations. The weight and balance of the aircraft are
factors that will affect all flight performance, and handling characteristics of the aircraft.
Find the actual licensed empty weight and CG of the aircraft on the Weight and
Balance Form. This document is required to remain with the aircraft and must reflect
any changes to the empty weight or CG. From that information and the instructions from
the POH, the pilot can determine the useful load and proper load distribution for the
aircraft.
Weight and Balance Procedure

1. Make a copy of the RV-12iS Weight & Balance Worksheet.
2. Drain all fuel from the tank.
3. Confirm that engine oil is at normal operating level.
4. Install both lower and upper cowl.
5. Check that all fairings, access covers/plates, etc. are fully installed.
6. Place seat cushions in the aircraft.
7. Check that there are no other items (tools, etc.) left in the cabin.
8. Roll aircraft onto 2 inch (5cm) blocks under main wheels and chock wheels.
9. Level the aircraft with reference to the canopy side rail/deck by inflating/deflating
nose tire or main tires as appropriate or by increasing or decreasing block thickness.
10. Drop a plumb line off the leading edge of each wing just outboard of main wheel
and mark a line on the floor between the two points.
11. Measure distance forward from left main wheel axle to the line on the floor and
record on the RV-12iS Weight & Balance Worksheet as D1.
12. Measure distance aft from nose wheel axle to line on floor and record on RV-12iS
Weight & Balance Worksheet as D2.
13. Measure distance forward from right main wheel axle to line on floor and record on
RV-12iS Weight & Balance Worksheet as D3.
14. Roll aircraft off blocks under main wheels. Place blocks on scale pads for main
wheels. Zero scales.
15. Roll aircraft onto scales using ramps. Verify canopy deck is level (adjust tire inflation
if/as necessary), close the canopy.
16. Record the left main wheel weight on RV-12iS Weight & Balance Worksheet as W1.
17. Record the nose wheel weight on RV-12iS Weight & Balance Worksheet as W2.
18. Record the right main wheel weight on RV-12iS Weight & Balance Worksheet as
W3.
19. On the RV-12iS Weight & Balance Worksheet, calculate empty weight, empty
moment, and empty arm.
20. Enter values for Empty Weight, Empty Moment, and Empty Arm into the table on
“YOUR AIRPLANE” table within RV-12iS Pilot Operating Handbook Section 6.
21. Place the RV-12iS Weight & Balance Worksheet in the aircraft as it is part of the
required documentation.
22. Enter values for Empty Weight, Empty Moment, and Empty Arm onto the Weight
and Balance Record page in this section.

RV-12IS WEIGHT & BALANCE WORKSHEET

AIRCRAFT: _________ (registration)_________ (serial number) DATE: _________
TABLE 1
LEFT WHEEL NOSE WHEEL RIGHT WHEEL
WEIGHT _______ lb _______ lb _______ lb

(W1) (W2) (W3)
DISTANCE FROM
AXLE CENTER TO _______ inches _______ inches _______ inches
LEADING EDGE (D1) (D2) (D3)
TABLE 2
WEIGHT ARM MOMENT
LEFT WHEEL _______ lb (70+_____ ) = ______inches ( _____ )*( _____ ) = _____ in-lb
(W1) (D1) (A1) (W1) (A1) (M1)
NOSE WHEEL _______ lb (70-_____ ) = ______inches ( _____ )*( _____ ) = _____ in-lb
(W2) (D2) (A2) (W2) (A2) (M2)
RIGHT WHEEL _______ lb (70+_____ ) = ______inches ( _____ )*( _____ ) = _____ in-lb
(W3) (D3) (A3) (W3) (A3) (M3)
EMPTY WEIGHT = ___________________ lb EMPTY ARM = __________________ inches

(W1 + W2 + W3) (Empty Moment / Empty Weight)
EMPTY MOMENT = __________________ in-lb

(M1 + M2 + M3)
Aircraft measured, weighed, and worksheet filled-out by: ___________________________

Printed Name/Title
___________________________
Signature

WEIGHT AND BALANCE RECORD
As of this date: ___/___/___ the following values represent current Weight and Balance
Calculations.
Revised Empty Weight: __________________ lb

Revised Empty Moment: __________________ in-lb
Revised Empty Arm: __________________ in
Signed: ___________________________
calculations resulting from the installation of the _______________________________.

Signed: ___________________________

Signed: ___________________________

Signed: ___________________________

INSTALLED EQUIPMENT LIST
INSTALLED
ITEM WEIGHT ARM MOMENT
lbs in. in-lbs.
DYNON
3.35 58.43
SV-HDX1100
DYNON (DUAL)
3.35 58.43
SV-HDX1100
DYNON
0.63 47.12
SV-EMS-220/221
DYNON
0.77 47.66
SV-XPNDR-261
DYNON
0.8 54.58
SV-BAT-320
DYNON
0.5 142.22
SV-ADAHRS-200
DYNON
0.44 43.13
SV-GPS-2020
GARMIN
2.37 54.55
GTR 200
ACK 406 1.18 96.18
ODYSSEY
14.38 43.56
PC680 BATTERY
EARTH X
4.9 43.56
ETX900 BATTERY
DYNON
0.3 123.26
SV-ADSB-472
DYNON SV AP /
0.3 58.49
KNOB PANEL(s)
DYNON
AUTOPILOT SERVO 2 78.6
(PITCH)
DYNON
AUTOPILOT SERVO 2 124.83
(ROLL)
TOTAL --------
SKYVIEW
INSTALLED
lbs. in. in-lbs.
TRIG
2.09 55.00
TY96
TOTAL --------
SKYVIEW

INSTALLED
lbs. in. in-lbs.
GARMIN
4.6 58.00
GDU 460
GARMIN
0.68 59.27
GMC 507
GARMIN
0.71 47.63
GEA 24
GARMIN
2.5 51.51
GTX 35R
TCW
1.125 55.31
IBBS-12V-3AH
GARMIN
0.48 119.00
GSU 25
GARMIN
0.42 42.93
GA 26X
GARMIN
2.37 54.42
GTR 200
ACK 406 ELT 1.18 133.25
EARTH X
4.9 43.56
ETX900 BATTERY
GARMIN
0.5 42.93
GA 36 OR GA 37
GARMIN
.67 52.85
GPS 20A
GARMIN
0.78 125.45
GDL 50/52R
GARMIN
AUTOPILOT SERVO 1.4 78.72
(PITCH)
GARMIN
AUTOPILOT SERVO 1.4 125.75
(ROLL)
TOTAL --------
G3X

INSTALLED
lbs. in. in-lbs.
GARMIN
0.16 142.26
GMU11
GARMIN
5.5 54.02
GTN650Xi
GARMIN
0.38 52.85
GAD29
GARMIN
1.78 55.57
GMA245
RAMI
0.88 219.98
AV-532L
TRIG
2.09 55.00
TY96
TOTAL --------
G3X

Chapter 2 - SERVICE SCHEDULE
OVERVIEW
Adherence to the service schedule is essential for maintaining airworthiness and
maximizing aircraft longevity. There are specific requirements for who can perform line
maintenance, heavy maintenance, or annual condition inspections on an S-LSA.
● NOTE: OWNERS WHO POSSES A SPORT PILOT CERTIFICATE (OR HIGHER) ARE AUTHORIZED
BY THE FAA TO PERFORM SOME LINE MAINT. TASKS. REFER TO FAR 43, APPENDIX A FOR
GUIDANCE
At least one of the following qualifications is necessary to perform line
maintenance on an S-LSA RV-12iS:
i The owner or operator provided they are Sport Pilot certified or higher.
i A person certified as “Repairman (light-sport aircraft)-Maintenance rating”
i An FAA certificated A&P mechanic.
At least one of the following qualifications is necessary to perform heavy
maintenance on an S-LSA RV-12iS:
i A person certified as “Repairman (light-sport aircraft)-Maintenance rating”
with task specific training.
i An FAA certificated A&P mechanic.
All Inspection and maintenance practices and all inspection and maintenance log
entries must be made in accordance with pertinent FARs and the manufacturers'
specified requirements.
● NOTE: FOR THE SERVICE SCHEDULE CHECKLIST SEE SUPPLEMENT PAGE 18-3.

The service schedule checklist serves as an index of the 'Service Procedures'

section of each applicable chapter. The 'Service Procedure' section includes the
recommended tools to complete each task. Applicable hardware will be stated using the
most general terms. Refer to the KAI for the specific hardware size, location, and
configuration. Manufacturers of third-party components determine service procedures
for those components. The manual provided by the manufacturer for that component is
the reference for service procedures. All component manuals are included with the
aircraft at the time of purchase.
The ‘What’ column in the Service Schedule Checklist provides the name of the
part or components to which the action applies.
The ‘Action’ column will indicate what is necessary; replace, lubricate, clean,
charge, etc.
The ‘When’ column specifies the time or use interval that may elapse before the
action is necessary.
The ‘How’ column will direct you to the chapter or manual that includes the
instructions, tools, supplies, and the level of certification required of the person
performing the action, for the given action.
Write the date of completion in the ‘Service Date’ column. Use the ‘Initial’ column
to identify the person that performed the service.

Chapter 3 - INSPECTION
OVERSTRESS ........................................................................................................................................... 3-1
OVERVIEW................................................................................................................................................ 3-2
INSPECTION DESCRIPTION ......................................................................................................................... 3-3
Special Tools .................................................................................................................................. 3-3
Pre-inspection / Post-inspection ......................................................................................................... 3-3
Cockpit ................................................................................................................................................ 3-5
Radio................................................................................................................................................... 3-6
Communication............................................................................................................................... 3-6
Intercom .......................................................................................................................................... 3-6
Transponder ................................................................................................................................... 3-6
Optional Equipment ............................................................................................................................ 3-7
Emergency Locator Transmitter ......................................................................................................... 3-7
Propeller.............................................................................................................................................. 3-7
Engine ................................................................................................................................................. 3-8
Firewall Forward ................................................................................................................................. 3-8
Empennage....................................................................................................................................... 3-10
Vertical Stabilizer .......................................................................................................................... 3-10
Rudder .......................................................................................................................................... 3-11
Stabilator....................................................................................................................................... 3-11
Anti-Servo Tab & Pitch-trim Servo................................................................................................ 3-11
Fuselage ........................................................................................................................................... 3-12
Landing Gear .................................................................................................................................... 3-13
Wing / Center Section ....................................................................................................................... 3-14
Rear Spar Doubler ....................................................................................................................... 3-15
Angle-Of-Attack................................................................................................................................. 3-16
Paperwork ......................................................................................................................................... 3-17
OVERSTRESS
In the event that the airframe’s allowable flight load factor is exceeded, as
indicated by the G Meter reading outside the parameters listed below, the airframe must
be inspected for possible damage due to an overstress condition. This inspection must
be performed by an individual with the minimum qualifications listed and an appropriate
log book entry made. Damage caused by the overstress which affects airworthiness
must be repaired before the next flight.
Category Limit Load Factor

Light Sport Category 4.0g/-2.0g
Minimum Certification LSA-RM or A&P

Additional KAI, POH (load factor)
References

OVERVIEW
The condition inspection is performed annually or every 100 hours of operation,
depending on the terms of use for the aircraft. The condition inspection is essential for
insuring safe operation throughout the aircraft's service life. In order for anyone to
perform a condition inspection on an S-LSA category RV-12iS aircraft they must
possess at least one of the following SPECIFIC CERTIFICATION REQUIREMENTS:
i A person certified as “Repairman (light-sport aircraft)-Maintenance” rating

i FAA certificated A&P technician
● NOTE: FOR THE INSPECTION CHECKLIST SEE SUPPLEMENT PAGE 18-7.
x NOTE: This maintenance manual is intended to be used in conjunction with the

RV-12iS Kit Assembly Instructions (KAI) when completing maintenance or repair
processes.
The inspector will identify any wear, corrosion or damage that would compromise
the safe operation of the aircraft. All inspection practices must comply with the current
Advisory Circular 43.13-1B regardless of the content of this manual.
During the inspection, locations concealed from direct line of sight may be
accessible by touch or with use of a mirror. Inaccessible places do not require
inspection provided the airframe has been constructed and used within the terms
defined by the manufacturer.
The Inspection Checklist provided in the Supplement will be a guide for the
inspection procedure. The bold print identifies each category of inspection and the
general symptoms to check for throughout that category. Each category inspection item
identifies specific things to check for with that item. Generally the items on the
Inspection Checklist will correspond to the bulleted items in this chapter. It is always
important to be generally observant to the condition of the aircraft regardless of what is
specified for inspection.
During the inspection make note in the space provided or on a separate
document of any discrepancies with parts, components or fasteners that require service
or replacement. Complete the entire inspection prior to performing service or repairs.
This chapter recommends tools that are useful for each inspection category.

INSPECTION DESCRIPTION
SPECIAL TOOLS
i Wing Retention Pin Bushing Gauge i Multi-meter
i Jack i Compression tester
i Padded stands i Carburetor vacuum gauges
i Step ladder i Torque wrench (in/lbs & ft/lbs)
i Tensile weight scale i Tire pressure gauge
PRE-INSPECTION / POST-INSPECTION
Perform the preliminary systems check and engine run-up as detailed in the
Inspection Checklist. The Rotax line maintenance manual provides the run-up
procedure for the engine. Test all of the engine systems and controls. Test all of the
airframe systems and controls. Make note of any abnormalities or dysfunctional
components. Record the applicable values in the spaces given on the Inspection
Checklist. After the systems check, proceed with the following:
Service rating Line
Minimum Certification LSA-RM, or A&P
■ CAUTION: ALWAYS SUPPORT THE FLAPERON DURING WING REMOVAL AND

STORAGE.
1. Remove the left and right wing. (5-12)

2. Remove all access covers, inspection plates, fairing and cowling shown in
Figure 4.

Figure 4: Remove for inspection

*Ref. Name *Ref. # Name
#
1 Right Wing 12 Left Wing
2 Upper Fwd Fuse Skin 13 Cover Plates (6)
3 Fuselage Side Cover (2) 14 Baggage Floor Cover
4 Top Cowl 15 Baggage Cover
5 Spinner 16 Baggage Bulkhead Corrugation
6 Bottom Cowl 17 Lower Tailcone Fairing
7 Tunnel Fwd Side Cover 18 Upper Tailcone Fairing
8 Tunnel Aft Side Cover 19 Forward Skin
9 Seat Floor Cover 20 Fuel Tank Assembly (see chapter 13
10 Flap Motor Cover for draining the fuel tank)
11 Access Hatch * - Not numbered in order of removal
3. Perform visual inspection for and make note of any oil, exhaust, fuel, hydraulic
fluid leaks.
4. Thoroughly clean engine, fuselage, cockpit, undercarriage and other areas as
needed to allow thorough inspection.
5. Throughout the inspection check for cracks, signs of fatigue, corrosion, wear,
deformation, and/or failure. Always check condition and security of all safe-
tied fasteners.

COCKPIT
x Inspect the aft face of the firewall for corrosion, deformation or cracks, especially
around fasteners.
x Inspect the welded rudder pedal assemblies for cracks / damage, smooth movement
with no heavy resistance, etc.
x Test the operation of the brake pedals. With constant pressure they should feel firm
and not spongy. Without pressure, each brake pedal must automatically return to the
original position. Check for hydraulic fluid leaks.
x Actuate the control stick forward and aft and left and right. Operation must be
smooth from stop to stop. Verify freedom of movement of the pulleys and confirm
that they turn smoothly and without lateral play. With the control stick pulled back the
trailing edge of the stabilator must be up.
x Run a rag along the control cables to check for frays or broken strands that will snag
the cloth. The stabilator cables must be aligned with the corresponding pulley and
free from physical interference. Confirm that the locking clips on the tensioner
barrels are installed and secure.
x Hold either control stick stationary and gently wiggle each push/pull rod; there must
not be free play or loose parts. Check the rod-end jam nuts for proper torque and
check the security of the rod-end connection fasteners.
x Make sure the stabilator

contacts its up and
down stops before the
WD-1210 Control
Column contacts it’s up
and down stops. If not,
loosen and tighten the
stabilator cable
tensioner barrels an
equal and opposite
amount until the travel
is full and correct. The
control column stops
must limit excessive
forward and aft
pressure. The bellcrank
stops must limit the left
and right control stick
motion. See Figure 5.
Figure 5: Control Stops

x Inspect each Seat Belt Harness latching mechanism, the condition of the webbing
material, and all stitching for damage or wear.
x Check the installation, fasteners and condition of each seat back.
x Inspect the canopy windscreen and aft window for deterioration or breakage. The
canopy latch and latch block must be in good condition and installed correctly. Test
the security of the roll bar and check for any sign of fatigue. Check the canopy frame
for cracks / security.
x Check that the control panel items are marked permanently, clearly, and correctly.
x Inspect all switch panel and instrument panel connections for security and condition.
x Check the condition of in-service fuses and the condition and presence of spare
fuses.
x Actuate the vent door on each side of the cockpit and confirm that it seals properly
when fully closed. Actuate each cabin heat push/pull control, confirm a clear
passage to the cabin (when 'On'), and smooth operation. Confirm that the heat door
has a tight seal to the firewall when each heat control is in the off position.
x Test the full motion of the engine throttle control for smooth operation and proper
operation of the friction control.
x Test for proper operation of the fuel on/off valve. Confirm arm on valve moves to
fully open position when on position of the control is selected. Leave valve in the off
position.
x Inspect all wiring harnesses for signs of chaffing, insecurity, etc.
x Inspect all system lines (Fuel, Brake) for signs of leaks at all fittings, abrasion, etc.
x Inspect all Fuel System components for security and leaks.
x [ULS] Confirm fuel valve in the off position. Disassemble Gascolator for inspection
and cleaning of filter screen. Re-safety at reassembly.
x [iS] Confirm fuel valve in the off position. Replace fuel filter at intervals specified in
the Service Schedule Checklist
AVIONICS
x Check the connections, external condition, and installation of each component; the
main unit, the antenna and the jacks. Check manufacturer’s web site(s) for updates
to operating software and install as appropriate.
COMMUNICATIONS
x Test the operation of the unit per manufacturer specs. (Refer to the Garmin or
Dynon installation manual)
TRANSPONDER
x Make sure the transponder is in compliance with FAR 91.403 and confirm that there
is a current maintenance log entry.

OPTIONAL EQUIPMENT
x Confirm that optional equipment installed on the aircraft is correct and authorized.
Optional equipment is offered and installed on the aircraft by the manufacturer at the
time of purchase. Refer to the related manual for special procedures for inspection.
(See applicable manual provided with the component)
EMERGENCY LOCATOR TRANSMITTER

x The ELT must be inspected in compliance with the FAR Part 91.207 (d) and
accompanied by a logbook entry. Refer to the manufacturer’s documentation for
battery replacement intervals for the ELT Remote Control Panel Indicator and for the
ELT Audio Alert Indicator.
PROPELLER
(Refer to Sensenich Propeller manual for complete inspection requirements)
Special Tools
i Torque wrench i Blade pitch
measuring tool
▲ WARNING: THE MASTER POWER AND BOTH IGNITION SWITCHES MUST BE SHUT
OFF DURING INSPECTION OF THE PROPELLER. SERIOUS INJURY OR DEATH WILL
RESULT IF ENGINE IS UNINTENTIONALLY STARTED BY TURNING THE PROPELLER.
x Check the spinner cone and back-plate fasteners for wear and security.
x Inspect hub and fasteners for cracks and wear.
x Check the pitot tube and bushing for wear and condition.
x Check hub fastener torque.
x Inspect the leading edge of the blades for loose metal. Inspect each entire blade for
cracks, missing material, and delamination.
● NOTE: PERFORM THE PROP TRACK TEST WITH THE SPARK PLUGS REMOVED.
x Test prop track by placing a stationary object in contact with the forward or aft face
of one of the blade tips. Then rotate the propeller to bring the opposite blade to the
same point. An off-track propeller will not come to the same point.

ENGINE
(Refer to Rotax manual)
OFF DURING INSPECTION OF THE ENGINE, UNLESS INSTRUCTED OTHERWISE. SERIOUS
INJURY OR DEATH WILL RESULT IF ENGINE IS UNINTENTIONALLY STARTED.
▲ WARNING: ALLOW THE ENGINE AND APPLICABLE COMPONENTS TO COOL
BEFORE PERFORMING SERVICE OR INSPECTION. HOT ENGINE COMPONENTS WILL
CAUSE SERIOUS BURNS.
x Refer to the Rotax line maintenance manual for proper inspection procedure for
engine and components supplied with engine. The Rotax manual will also provide
fluid check and change procedure.
FIREWALL FORWARD
OFF DURING INSPECTION OF THE FIREWALL FORWARD COMPONENTS. SERIOUS INJURY
OR DEATH WILL RESULT IF ENGINE IS UNINTENTIONALLY STARTED.
▲ WARNING: ALLOW THE ENGINE AND APPLICABLE COMPONENTS TO COOL
BEFORE PERFORMING SERVICE OR INSPECTION. HOT ENGINE COMPONENTS WILL
CAUSE SERIOUS BURNS.
Special Tools
i Multi-meter
x Note any signs of leakage, corrosion, and excessive temperature of components.

Check for wear to hoses, cables, wiring harnesses, etc. as a result of vibration while
in contact with another object.
x Check the forward side of the firewall, especially around components and fasteners,
around the battery, oil tank assembly, cowl attach locations, engine mount, and nose
gear. The firewall must not have any open passages into the cockpit.
x Inspect the engine mount for damaged coating, corrosion and signs of fatigue or
cracks. Damaged engine mount coating demands closer examination and repair.
x Inspect the engine vibration isolators for cracks, deterioration and installation.
x Inspect the engine mount and vibration isolator hardware for damage and
looseness.
x Check the engine compartment wiring, including ground wires of the wiring harness
and battery. Wire insulation must be secure, intact and flexible; free from cracks,
burns, or separation. All wire terminations must be tight.

x Check the battery for proper voltage, condition of the case, and that the connections
are secure.
x Cabin heat cables and connections must be secure and operate smoothly. All SCAT
ducting must be secure and in good condition. Heat valve doors must close tightly
against firewall (when 'OFF').
x Check the engine throttle control cable for security and condition along the route to
the firewall. The throttle must be securely connected to the throttle body and be in
good condition. Confirm that the Throttle control operates the throttle body arm
through its entire travel range from stop-to-stop.
x Inspect the air filter and SCAT hose for cleanliness, attachment and condition. Clean
and re-oil the filter as required.
x Inspect the heat exchangers for proper attachment, cleanliness, condition, and signs
of leakage. Inspect all mounting brackets and rubber isolators for security and
cracks, and confirm fasteners are safetied.
x Evaluate the age of hoses and other rubber components in the engine compartment.
All hoses and other rubber components provided with the engine have a service life
defined in the Rotax maintenance manual. Service life of all other hoses and
components are specified in the Service Schedule Checklist.
x The Pitot and other flexible hoses or lines must be in good condition, connected and
fastened securely, and no evidence of abrasion or wear along their length.
x Check the fuel and oil and coolant hoses for good condition; secure mounting,
routing and tight connections.
x Check the muffler heat muff for damage and indications of abrasion wear on the
outer surface of the muffler.
x Check exhaust system ball joints for proper anti-seize lubrication.
x Inspect the cowling for overall condition; loose paint, material separation, signs of
wear. Check the cowl fasteners and hinges for missing eyelets, security. Check cowl
shielding for signs of high temperature and proper attachment to cowl.

EMPENNAGE
x Inspect the exterior of the

fuselage skins and fasteners.
Check the fasteners by sighting
along each rivet pattern for any
inconsistent rivet profile among
properly installed rivets as
shown in Figure 6.
Figure 6: Rivet Inspection
VERTICAL STABILIZER
x Check the main skin and forward skin for deformation or cracks.
x Check the main skin fasteners by sighting along each rivet pattern for any
inconsistent rivet profile among similar properly installed rivets.
x Check the forward spar and fasteners for cracks, deformation and signs of fatigue.
x Inspect the rear spar, spar fasteners, and hinges for cracks, deformation and signs
of fatigue, especially the areas surrounding the rudder hinge brackets.

x Check the fiberglass fairing for condition and security.

x Check for interference or signs of wear from the rudder.
x Look through the forward spar lightening holes to inspect the rear spar, ribs, and rib
flanges for cracks.
RUDDER
x Check the main skin for damage or deformation.
x Sight along each rivet pattern for any inconsistent rivet profile among similar properly
installed rivets.
x Check the spar and hinge brackets for cracks, deformation and signs of fatigue,
especially the areas surrounding the hinge brackets.
x Check the fiberglass fairing for condition and security.
x Check the rudder control horn for coating damage. Inspect for cracks, missing
fasteners and deformation on the control horn and rudder bottom rib.
x Inspect the control cable swages, link fasteners and attach area on the control horn
for signs of wear or fatigue.
x Check the rudder stops on the lower hinge for wear or deformation.
x Make sure the rudder swings smoothly.
STABILATOR
x Check the skins for damage or deformation.
x Check the main skin fasteners by sighting along each rivet pattern for any
x Inspect the Anti-Servo Tab hinges, fasteners, and safety wire for wear and security.
x Inspect the spar box for cracks, deformation or signs of fatigue, especially the areas
surrounding the control horns, hinge brackets, and counterbalance brackets.
x Use an Inspection mirror to inspect the ribs for cracks or deformation.
x Inspect the coating on the control horn brackets. If damaged, inspect for cracks.
x Inspect the control horns and fasteners for wear and security.
x Check the control cable fasteners for security and signs of wear.
x Check the counterbalance arm for straightness and for interior/exterior corrosion.
Make sure the counterbalance weights are secure and the fasteners are in good
condition.
x Inspect the hinge brackets, stops, and fasteners for signs of wear and security.
x The stabilator must swing smoothly and be limited only by the hinge stops. Make
sure that both hinge brackets on the tail cone contact their corresponding hinge stop
on the stabilator squarely and simultaneously, just prior to the control stick hitting its
stops.
ANTI-SERVO TAB & PITCH-TRIM SERVO

x Check the anti-servo tab skins for damage or deformation.
x Check the anti-servo tab fasteners by sighting along each rivet pattern for any


x Check the spar and attach hinge for deformation and signs of fatigue.
x Inspect the control horns and surrounding area for deformation, cracks, and signs of
fatigue. Check the control horn fasteners for wear and security.
x Inspect the pitch-trim servo push rod and link for damage or signs of fatigue, and
play in hardware connection points. There should be very little movement in the tab
when the stabilator is held fixed.
x Inspect the pitch-trim servo, and servo tray for deformation or cracks.
x Check the fasteners and bushings that connect the pitch-trim servo tray to the tail
cone for security and wear. There should be very little movement in the tab when
the stabilator is held fixed.
x Check the electrical connections and wire for condition and wear.
x Test the operation of the AST by actuating the stabilator through its full range of
motion with the trim adjusted to the full nose up and full nose down settings. AST
movement must be smooth and relative to the stabilator movement. There must not
be any interference with the AST and the pitch-trim servo components at any point
of the stabilator travel. Check the electrical connections and wire for condition and
wear.
FUSELAGE
x Pay particular attention to the areas where the firewall attaches to the fuselage, each
wing spar mates with the fuselage, the tailcone attaches to the forward fuse, and the
empennage components attach to the tailcone.
x Visually inspect that both of the static ports are clear.
x Test the condition and security of the left and right boarding steps.
x Inspect the condition of the electrical connections that correspond to the wing. The
connections must be free of corrosion and any damage.
x Inspect the inside diameter of each flaperon torque tube for rust/corrosion and verify
that the UHMW plastic spacers are in place in the actuating arms of the flaperon
torque tubes.

LANDING GEAR
▲WARNING: A LIFTED AIRCRAFT MUST BE SECURELY SUPPORTED BY STATIC
STANDS OTHER THAN THE JACKING DEVICE. THE AIRCRAFT MAY NOT MOVE FROM
ATTEMPT TO SHAKE HORIZONTALLY OR VERTICALLY.
■CAUTION: ALWAYS USE PADDED STANDS AND ALWAYS DISTRIBUTE THE LOAD
ALONG A RIVET PATTERN WITH SEVERAL INTERSECTING RIVET PATTERNS.
●NOTE: REFER TO GENERAL – GENERAL PROCEDURES INDEX FOR INSTRUCTIONS
ON LIFTING AND SUPPORTING THE AIRCRAFT.
Special Tools
i Torque wrench i Saw horses
i Tensile weight scale
x Check all landing gear components; attach locations, and fasteners for cracks and
any other signs of fatigue. Throughout the inspection of the main landing gear, be
observant for signs of hydraulic fluid leakage from the brake lines or fittings.
x Inspect each landing gear-leg and attach point. Check for evidence of black dust at
the attach points which is an indicator of movement.
x Test the security of each of the landing gear-legs. The landing gear components
may not have any free play in any direction.
x Check that all attach hardware is at proper torque. Remember to account for the
prevailing torque of the nut. If a torque wrench is used on the head of the bolt also
account for the torque to overcome the friction to turn the bolt shank within the
assembly.
x Check the main U-1220 gear legs for corrosion or bubbled paint that may lead to
corrosion.
x Test the security of the brake lines and inspect for signs of wear.
x Grab and shake the wheels and tires to check for bearing looseness.
x Check for smooth, low resistance rotation of each wheel.
x Check for excessive play in both brake calipers.
x Check the brake shoe linings, brake disc and wheel assembly per Matco
manufacturer specifications.
x Use a straight edge to check that each unloaded gear-leg is straight, between the
factory bends.
x Inspect the condition of fasteners and cotter pins at the location of all three wheel
axles.
x Inspect the tires for cracks, wear, and tire pressure, and each valve and valve stem
in good condition, and capped.
x Check the nose gear-leg coating, welds, and brackets for cracks and signs of

fatigue.
x Remove the nose fork from the nose gear leg. Clean and inspect for corrosion or
wear. Re-lube and reinstall. Check the break-out force per KAI, and safety with a
new cotter pin.
WING / CENTER SECTION

Special Tools
i Wing retention i Multi-meter
pin bushing gauge
x Inspect the wing skins and fasteners for signs of damage or deformation. Check the
fasteners by sighting down each rivet pattern for any inconsistent rivet profile among
properly installed rivets. Any damage observed on the wing skins demands thorough
inspection of the understructure of the damaged wing.
x Use a flashlight and an inspection mirror to inspect spars, ribs and attach angles on
the interior of each wing. Especially the inboard-most ribs and ribs at the flaperon
hinge attach points. The aft outboard portion of the wings can be viewed through
the lightening holes in the outboard portion of the rear spar.
x Inspect the main spar, rear spar and stub spar for corrosion, deformation, signs of
wear or fatigue. Inspect the rear spar and stub spar for lubrication at the inboard
end.
x Inspect the flaperon condition and operation. Inspect the flaperon skins and
fasteners for damage or deformation. The flaperon must swing smoothly without free
play in any direction. Inspect the flaperon control connection for signs of wear.
Check the fasteners in the flaperon hinge brackets on each wing for security. Inspect
inner surface of flaperon torque tubes for rust and corrosion.
x Inspect the condition of the electrical connections that correspond to the fuselage.
The connections must be free of corrosion and damage.
x Test the stall warning Vane for freedom of movement. Check the micro-switch for
corrosion, condition and security. Check the wing skin for cracks around the stall
warning vane penetration.
x Test the AOA system plumbing for leaks. See the AOA System Test section below.
x Check fuselage pin latching mechanisms for security and proper operation. Test
warning circuit by moving each latch independently and verifying warning light.

x Inspect each fuselage pin and all wing

retention pin bushings for wear or
cracks. Inspect the center section area
around the bushings for deformation or
cracks. Use the Main Spar Bushing
Gauge Pin to check the wear of both
ends of all of the wing retention pin
bushings. Insert the Gauge Pin into the
bushing, and then rotate the Gauge
Pin. The Gauge Pin is a 'go, no-go'
device. If the 'no-go surface' contacts
the bushing (or mounting surface), the
wing retention pin bushing must be
replaced. See Figure 7. Figure 7: Wing Retention Pin Bushing
x Inspect the center section channel, bulkheads, fasteners and stiffeners for signs of
damage or fatigue. Check the center section left and right UHMW retainer block and
roller for security and wear.
x Check the fuselage pin latching mechanisms for security and proper operation. Test
the warning circuit by unlatching each pin individually to verify it causes the switch
panel warning light to illuminate.
REAR SPAR DOUBLER

x If the W-1207B rear spar doubler has been trimmed too much, the finished airplane
may exhibit some play at the rear spar junction. This is usually discovered by
hearing a “click” and detecting in/out movement when the wing is installed.
Increasing the length of the spar doubler is not possible, so it must be removed and
replaced with a different, slightly longer, part.
x To determine which part is required, measure the in/out movement of the wing. This
will require two people.
x Begin by chocking the tires firmly, so the fully assembled airplane rocks and moves
as little as possible.
x Attach a dial caliper to the inboard wing skin as shown below and adjust it so it just
touches the side of the fuselage. (Use a spacer between the caliper and the wing
skin, if necessary, to clear the rubber wing root seal). One person can rock the
wingtip forward and aft while the other checks the indicator, and measures the total
play.

x If the measurement is less than 0.050 no repair is required.

x If it is 0.050 or more refer to repair instructions in Section 5.
Figure 7.1: Inspect Rear Spar Doubler
ANGLE-OF-ATTACK SYSTEM TEST

Special Tools
i Syringes - two req'd (35cc or similar) iModeling clay
i Vacuum hose (or soft plastic tubing)
NOTE: IF EQUIPPED WITH FLF-00015 AOA WING ROOT RECEPTACLE, THE AOA
SYSTEM PLUMBING MUST PASS THIS LEAK TEST DURING EVERY INSPECTION AND
EVERY TIME THE WINGS ARE REMOVED AND INSTALLED.
IF EQUIPPED WITH FLF-00015-1, COMPLETE AOA SYSTEM TEST EVERY 24

CALENDAR MONTHS.
THE FLF-00015-1 CAN BE IDENTIFIED BY THE PRESENCE OF AN O-RING INSIDE

THE AOA WING ROOT RECEPTACLE. THE FLF-00015 DOES NOT HAVE AN O-RING.
WHEN PERFORMING ANY AOA, STATIC, OR PITOT SYSTEM PRESSURE TEST ON A

DYNON SKYVIEW SYSTEM IT IS REQUIRED TO BE AT SOFTWARE VERSION 15.0.4
(OR GREATER) AND ALL TESTING MUST BE PERFORMED IN THE SETUP MENU >
HARDWARE CALIBRATION > ADAHRS CALIBRATION > PITOT/STATIC TEST MODE.
After the AOA system has been properly calibrated in flight, this test is used to test the
AOA system plumbing integrity, as required above.
x Using a 35cc syringe push plunger in to 7.5cc, hook-up syringe & vacuum hose to
pitot tube, turn-on EFIS, use syringe to slowly, carefully push air into pitot, look for
airspeed indication on EFIS, push-in syringe until 130 kts indicates then stop.

x Using a second syringe push plunger in to 7.5cc. Use modeling clay to hook-up the
syringe and vacuum hose to the AOA port.
x Pressurize the AOA port. Watch the EFIS AOA indicator. Increasing AOA port
pressure will cause the EFIS AOA indicator to move from green to red. Do not apply
more pressure than necessary to move the AOA indication into the red zone. Once
the AOA indication is in the red zone stop pushing in the syringe.
x Move the left wing tip back and forth while performing the AOA system leak test to
verify AOA system integrity.
x The maximum allowable AOA system leak rate is less than full AOA indicator scale,
from red to green, in one minute.
x If the AOA system does not hold test pressure for the required time inspect the
modeling clay to wing seal before inspecting other AOA system components. Inspect
and repair or replace any faulty AOA system components, as necessary. If faulty
components were replaced or repaired re-test the AOA system plumbing integrity.
PAPERWORK
x Make the appropriate log book entries.
x Save the completed checklist in the aircraft file.


Chapter 4 - STRUCTURAL REPAIRS
OVERVIEW
Visible deformation of or damage to any aircraft skin warrants a complete
inspection of the underlying parts or structures. If all damaged parts are replaced in
accordance with the Kit Assembly Instructions KAI no consultation of the manufacturer
is necessary.
Small patch repairs to skins as outlined in AC 43.13 are allowed without consulting the
aircraft manufacturer if the total patch area does not exceed 60 square inches. Repair to
interior structural parts of the airframe or skin repairs (other than replacement of the
entire skin or patches to skins) of more than 60 square inches are not allowed without
consulting with the airplane manufacturer and receiving approval of the planned method
of repair. Note: Integral stringers formed on the edge of skins are considered interior
structure.


processes.
xNOTE: For more information regarding riveting, metal working, fiberglass, fluid
fittings, priming, painting and more refer to the KAI Chapter 5; Construction
Materials, Processes & Useful Information.
x NOTE: Stop drill cracks per AC 43.13. Report any cracks to Van's Aircraft using
the feedback form found at the back of this manual.
MINIMUM CERTIFICATION
The minimum certification for completing a repair to aircraft skins is an LSA
Repairman – Maintenance or an FAA certificated A&P technician. Refer to the KAI to
identify individual parts and their corresponding part numbers.

Chapter 5 - STRUCTURES
OVERVIEW .......................................... 5-2 In Center Section:..................................5-13

In Wing Spars:.......................................5-14
FUSELAGE Canopy and frame removal ......................5-14
.......................................................... 5 Installation .............................................5-14
-2 ......................................................... Main wheel and tire assembly removal.....5-15
Installation .............................................5-15
Components................................ 5-3 Nose wheel and tire assembly removal ....5-16
WING AND FLAPERON ....................... 5-4 Installation .............................................5-16
Components................................ 5-5 Main inner tube replacement ....................5-17
Nose inner tube replacement....................5-17
EMPENNAGE..................................... 5-6 Flaperon hinge replacement .....................5-18
Components................................ 5-7 Rudder hinge replacement .......................5-19
LANDING GEAR ................................. 5-8 Stabilator hinge bearing replacement .......5-20
Main gear removal....................................5-22
Components................................ 5-9 Installation .............................................5-22
NOSE WHEEL & GEAR LEG FAIRINGS 5-10 Nose gear removal ...................................5-22
Components.............................. 5-10 Installation .............................................5-23
Belt and Harness replacement .................5-23
Wheel Fairings .......................... 5-11 Canopy latch block replacement...............5-23
Optional Components................ 5-11 Step replacement .....................................5-24
SERVICE ........................................ 5-12 Rear Spar Doubler Replacement..............5-24
Supplies .................................... 5-12 Service Schedule Procedures ... 5-26
Special Tools ............................................5-12 Wing attach location lubrication ................5-26
Expendable...............................................5-12 Fuselage pins........................................5-26
Replaceable..............................................5-12 Stub spar and Rear spar .......................5-26
AOA connector tube .............................5-26
General ..................................... 5-13 Flaperon control connection lubrication ....5-26
Wing removal............................................5-13 Flaperon bearings lubrication ...................5-27
Installation .............................................5-13 AST attach hinge lubrication.....................5-27
Wing retention pin bushing replacement...5-13 Nose wheel bearings replacement ...........5-27

Main wheel bearings lubrication ...............5-28 Wheel Assem. Balancing Procedure ........5-29
Nose fork pivot tension and lubrication .....5-28

OVERVIEW
The RV-12iS airframe uses blind (pop style) rivets as the primary fastener. Screws,
bolts and solid rivets are used where necessary. The wings are removable without the
need of tools.
x NOTE: PRIOR TO PERFORMING STRUCTURAL REPAIRS READ CHAPTER 4 FOR LIMITATIONS.
x NOTE: THIS MAINTENANCE MANUAL IS INTENDED TO BE USED IN CONJUNCTION WITH THE

RV-12IS KIT ASSEMBLY INSTRUCTIONS (KAI) WHEN COMPLETING MAINTENANCE OR REPAIR
PROCESSES.
▲WARNING: BEFORE PERFORMING ANY MAINTENANCE OR REPAIRS TURN THE

MASTER SWITCH 'OFF' AND DISCONNECT THE NEGATIVE (-) BATTERY CABLE FROM THE
BATTERY.
FUSELAGE
The fuselage will be identified as the forward fuselage and the tailcone. The forward
fuselage is the baggage bulkhead and all airframe parts forward to, and including, the
firewall. The tailcone refers to all of the parts behind the baggage bulkhead, excluding
the empennage fairing and empennage components.

Figure 9: Fuselage
COMPONENTS
Quantity Part or Assembly Name Part Number or Reference
1 Canopy and Frame C-1201 & WD-1219
1 Fuselage Refer to KAI
2 Fuselage Pin WD-1217
4 Wing Retention Pin Bushing W-1206U
1 Latch Block C-01205-3
2 Occupant Harness System See shaded items below & Refer to KAI
1 Shoulder Harness
1 Lap Belt
1 Crotch Strap
1 Left Step WD-1233-L-1
1 Right Step WD-1233-R-1

WING AND FLAPERON

The wing and flaperon are removable as an assembly from each side of the
fuselage. Each wing mates to the fuselage at three points; the stub spar, the main spar
and the rear spar. Two fuselage pins secure both main spars to the center section of the
fuselage. The left wing has a stall warning sender and AOA sensor port installed.
Electrical, AOA plumbing and control connections connect automatically during wing
attachment. With the wing detached from the fuselage, the flaperon is removable.
Figure 10: Wing and Flaperon

COMPONENTS
1 Left Wing See shaded items below & Refer to KAI
1 Stub Spar W-1208B-L / W-1208C-L
1 Rear Spar W-1207A-L / W-1207B
1 Stall Warning See 5-4 and KAI
1 Right Wing See shaded items below & Refer to KAI
1 Stub Spar W-1208B-R / W-1208C-R
1 Rear Spar W-1207A-R / W-1207B
1 Right flaperon Mirror of Left Flaperon (See below)
1 Left Flaperon See shaded items below & Refer to KAI
2 Flaperon Hinge MD3614M
1 Actuation Bracket A-1207-L
1 Pivot Guide A-1211

EMPENNAGE
The empennage components include the vertical stabilizer, rudder, anti-
servo/trim tab, and stabilator assemblies. The vertical stabilizer front and rear spar
attach to the tailcone. Fiberglass fairings finish the top of the vertical stabilizer, rudder
and are optional on the ends of the Stabilator. The rudder is attached through hinges on
the rear spar of the vertical stabilizer. The stabilator attaches to hinges on the aft
bulkhead of the tailcone. The AST attaches to the rear of and operates in sequence with
the stabilator. The AST also functions as a trim-tab.
Refer to the KAI for empennage component removal and installation.
Figure 11: Empennage

COMPONENTS
1 Vertical Stabilizer See shaded items below & Refer to KAI
1 Lower Hinge VS-1210 / VS-1211A / COM-3-5
1 Upper Hinge VS-1210 / VS-1211B / COM-3-5
1 Fwd Skin VS-1204
1 Rudder See shaded items below & Refer to KAI
1 Rudder Horn WD-1205
1 Stabilator See shaded items below & Refer to KAI
2 Hinge Bracket HS-01231A-1 / HS-01231B-1 / HS-01231C-1
1 Anti-servo / trim tab See shaded items below & Refer to KAI
2 AST Hinge HS-1218A / HS-1218B

LANDING GEAR
The landing gear includes the gear-legs, wheels and tires, nose fork and
mounting brackets. The nose gear-leg is steel, with welded brackets. The aluminum
nose fork attaches and pivots at the lower end. An axle bolt and nut fastens the axle,
spacers, and wheel and tire assembly to the nose fork. The main gear-legs are
aluminum, fastened to the center section channel with brackets and bolts. Each main
axle bolts to the lower end of each gear leg. All three tires are 5.00 x 5, either 4-ply or 6-
ply tube type aircraft tires are acceptable.
Figure 12: Landing Gear

COMPONENTS
1 Left Main Gear U-1220-L
1 Right Main Gear U-1220-R
2 Outbd. Main Gear Attach Brkt. U-01202-1
2 Outbd Wear Plate U-01202A
2 Inbd. Main Gear Attach Brkt. U-01203-1
2 Inbd. Wear Plate U-01203B-1
2 Doubler Plate U-01203C-1
2 Inbd. Doubler Plate U-01203E-1
2 Main Wheel assembly See shaded items below
1 Main Wheel U-MHMHE51B
2 Wheel Bearings BEARING LM-67000L-A
1 Axle MHE51B AXLE
1 Nose Gear WD-1201
1 Nose Fork WD-01230-1
1 Nose Wheel Assembly See shaded items below
1 Nose Wheel U-WHLNW51CC.625
1 Axle U-1210A-1
2 Spacer U-1210B-1
4 Wave Washer 5806-148-3
1 Wheel Bearing N/A
3 Tire U 5.00 X 5 TIRE
3 Tube U 5:00X5-6IT

NOSE WHEEL AND GEAR LEG FAIRINGS

The optional nose wheel and gear leg fairings include the glass fabric/epoxy
resin nose leg fairing, wheel fairing front and the wheel fairing aft. See Figure 13. The
nose leg fairing is clamped about the nose leg using a piano hinge held in place by a
single screw. The nose leg fairing is slotted to fit about the nose leg winching lug. The
wheel fairing aft attaches to the wheel fairing front which in turn attaches to the nose
fork. Tow bar access is provided by two 13/16 diameter holes in the wheel fairing front.
Figure 13: Nose Wheel and Gear Leg Fairings
OPTIONAL COMPONENTS
1 Wheel Fairing Front U-00005A
1 Wheel Fairing Aft U-00005B
1 Nose Leg Fairing U-00007

WHEEL FAIRINGS
The optional main wheel fairings include the glass fabric/epoxy resin wheel
fairing front and the wheel fairing aft. See Figure 14. The fairings are attached to the
wheel fairing brackets which in turn attach to the bracket mount.
MATCO
GROVE
Figure 14: Main Wheel Fairings
OPTIONAL COMPONENTS
2 Wheel Fairing Front U-00001A
2 Wheel Fairing Aft U-00001B
4 Wheel Fairing Bracket U-00002
2 Bracket Mount (inner) not shown U-00003
2 Bracket Mount (outer) U-00004

SERVICE
SUPPLIES
SPECIAL TOOLS EXPENDABLE

i Tensile weight scale i Cotter pins
i 1/4 drive socket slightly less than i Safety wire
5/8in in diameter. (A common i Wheel bearing grease
standard 7/16 socket generally i Spray lubricant
works). i Inner tube
i 3/8 drive, 3/4 socket i Hydraulic fluid
i Hex Bolt 1/4 diameter 3 inches i Loctite
long (must be threaded at least i Silicone Grease
50% of its length)
i 1/4 Flat Washer(2) and Hex Nut
i #30 drill bit REPLACEABLE
i Drill motor i See component lists on page:
i 1/8” clecos and pliers 5-3
i Blind rivet puller 5-9
i Rivet squeezer & dies i Canopy struts
i Bearing MD3614M
i Bearing DW4K2X
i Nose wheel bearings
i Main wheel bearings
i Nose fork bushings
i Pivot guide
i Upper rudder hinge
i Lower rudder hinge

GENERAL
WING REMOVAL
No special tools or certification required.
■ CAUTION: BE PREPARED WITH A HELPER OR SUPPORT STAND TO HANDLE THE
WEIGHT AND AWKWARDNESS OF THE OBJECT TO BE REMOVED.
■ CAUTION: ALWAYS SUPPORT THE FLAPERON DURING WING REMOVAL AND

STORAGE.
1. Retract the fuselage pin stopper on each fuselage pin and withdraw each of them
only enough to release the right wing spar. (Note: rotating the pin back and
forth while pulling makes removal easier).
2. Grasp the wing at the wing tip end, lift very slightly and pull while also holding the
Flaperon, to remove it from the fuselage and set it aside.
3. Fully remove both of the fuselage pins.
4. Remove the left wing using the same procedure and set aside.
● NOTE: THE AOA SYSTEM PLUMBING MUST PASS A LEAK TEST DURING EVERY
CONDITION INSPECTION AND EVERY TIME THE WINGS ARE INSTALLED AFTER REMOVAL
IF EQUIPPED WITH FLF-00015. (3-16)
INSTALLATION
1. Lubricate all wing attach and flaperon control locations as detailed on 5-26.
2. Installation procedure is the reverse of the removal procedure. (Install the left
wing first, right wing second). The wing root seal strip on the side of the fuselage
can be used to help align the wing at the proper angle of attack while inserting it
into the fuselage. The root end of the flaperon must be properly aligned with the
clevis portion of the flaperon torque tube for the wing to fully insert. (Note:
rotating the pin while pushing/hitting with the heel of your palm helps aid in
pin insertion.)
3. Complete the AOA leak test procedure, if required. (3-16)
WING RETENTION PIN BUSHING REPLACEMENT

Expendable None
Replaceable Wing Retention Pin Bushing
Service Rating Line
Additional KAI
References
1. Remove the wings.
IN CENTER SECTION:
1. Tap out the bushing from the non-flanged end of the bushing.

2. Tap the new bushing into place with the flanged end toward the wing spars.
IN WING SPARS:
3. Tap out the bushing from the non-flanged end of the bushing.
4. Tap the new bushing into place with the flanged end to be on the forward side of
the wing spar.
CANOPY AND FRAME REMOVAL

Expendable None
Replaceable Canopy and Frame
Canopy struts
Service Rating Line
Additional KAI
References
■ CAUTION: BE PREPARED WITH A HELPER OR SUPPORT STAND TO HANDLE THE

1. Open and support the canopy. (Easiest with a partner)

2. Remove the lower support strut hardware; bolts (2).
3. Remove the pivot hardware; bolts (2), and bushings (2).
4. Remove canopy and frame.
INSTALLATION
1. Installation procedure is reverse of the removal procedure.

MAIN WHEEL AND TIRE ASSEMBLY REMOVAL

Expendable Cotter pins
Safety wire
Replaceable None
Service Rating Line
Minimum Certification Owner and SPC, LSA-RM, or A&P
Additional References Matco User Manual
Grove User Manual
KAI
1. Lift and support the aircraft. (1-16)

2. Remove the stationary brake shoe bolts (2), washers (2), spacer and brake shoe.
3. Remove the cotter pin, axle nut, washer and wheel and tire assembly.
INSTALLATION
1. Installation procedure is reverse of the removal procedure. Refer to the Matco
User Manual for nut torque / bearing adjustment procedure.
NOSE WHEEL AND TIRE ASSEMBLY REMOVAL

Expendable None
Replaceable None
Service Rating Line
Additional References Matco User Manual
KAI
2. Remove the axle bolt, washers (2), nut, axle, spacers, wavy washers, and wheel

and tire assembly.
INSTALLATION
MAIN INNER TUBE REPLACEMENT – MATCO WHEEL (NOTE: THE

MATCO WHEEL ASSEMBLY IS IDENTIFIABLE BY IT HAVING A WHEEL HUB THAT IS SEPARATE FROM
THE TWO WHEEL HALVES)
Expendable Inner tube
Safety wire
Replaceable Main wheel assembly
Tire
Service Rating Line
Minimum Certification Owner and SPC, LSA-RM,
or A&P
Additional Matco User Manual
References KAI
2. Remove the main wheel and tire assembly. (5-15)
3. Remove the brake disc socket-head cap screws (3), and brake disc.
4. Deflate the inner tube.
5. Split the wheel assembly by removing the socket head cap screws (6), washers
(9), and nuts (6).
6. Coat the replacement tube and tire interior with tire talc and install the
replacement inner tube in the tire. Orient the valve stem to the hole in the wheel
and the colored dot on the tire. Re-install the wheel in reverse of disassembly.
7. SLOWLY inflate the tire. Deflate it fully and re-inflate it SLOWLY a couple more
times to work out any wrinkles in the tube. Inspect for a good seat around the
wheel rim. For final inflation pressure see page 1-14.
8. Reassemble and install the wheel and tire assembly.

MAIN INNER TUBE REPLACEMENT – GROVE WHEEL (NOTE: THE

GROVE WHEEL CAN BE IDENTIFIED BY HAVING BEARING HUBS THAT ARE INTEGRAL WITH THE
WHEEL HALVES).
Safety wire
Replaceable Main wheel assembly
Tire
Service Rating Line
or A&P
Additional Grove User Manual
References KAI
2. Remove the main wheel and tire assembly. (5-15)3.
5. Split the wheel assembly by removing the AN bolts (3), washers (3), and nuts (3).
replacement inner tube in the tire. Orient the valve stem to the hole in the wheel
and the colored dot on the tire. Re-install the wheel in reverse of disassembly.
NOSE INNER TUBE REPLACEMENT

Replaceable Nose wheel assembly
Tire
Service Rating Line
or A&P
Additional References Matco user manual
KAI
Lift and support the aircraft. (1-16)

1. Remove the nose wheel and tire assembly. (5-16)
3. Split the wheel assembly by removing the bolts (3), washers (6), and nuts (3).
replacement inner tube. Orient the valve stem to the hole in the wheel and the
colored dot on the tire.

FLAPERON HINGE REPLACEMENT

Expendable Loctite 243 or Equiv.
Replaceable Bearing MD3614M
Service Rating Line
Additional References KAI
■ CAUTION: BE PREPARED WITH ADDITIONAL PERSONEL OR TOOLS TO HANDLE THE

1. Remove the wings. (5-13)

2. Make note of the flaperon hinge hardware configuration
3. Remove the flaperon hardware and flaperon assembly.
4. Measure and
record the hinge
bearing
protrusion
measurement
as shown in
Figure 15.
Figure 15: Flaperon hinge
5. Remove the flaperon hinge bearing from the wing.

6. Install the new flaperon hinge bearing to the same protrusion measurement after
application of thread locker as detailed in KAI.
7. Install the flaperon assembly.

RUDDER HINGE REPLACEMENT

Expendable None
Replaceable Lower rudder hinge
Upper rudder hinge
Service Rating Line

1. Remove the upper and lower tailcone fairing. (3-4)

2. Remove the rudder control cables and rudder assembly.
3. Remove, from the vertical stabilizer, the rudder hinge hardware (see below) and
the rudder hinge to be replaced;
i Upper hinge; bolt (4), washer (8)
i Lower hinge; bolt (4), washer (4)
■ CAUTION: UPPER AND LOWER RUDDER HINGES ARE NOT INTERCHANGABLE .
4. Install the new rudder hinge and hardware.

5. Install the rudder assembly.
6. Install the upper and lower tail cone fairing.

STABILATOR HINGE BEARING REPLACEMENT

Special Tools 1/4 drive socket slightly less than
5/8in in diameter. (A common
standard 7/16 socket generally
works).
3/8 drive, 3/4 socket
Hex Bolt 1/4 diameter 3 inches
long (must be threaded at least
50% of its length)
1/4 Flat Washer(2) and Hex Nut
Lock Clips (2)
Loctite 648
Replaceable Bearing DW4K2X
Service Rating Line
Additional KAI
References

Removing the Stabilator

● NOTE: BEFORE DISCONNECTING THE STABILATOR CONTROL CABLES BE

PREPARED TO PREVENT THE ENDS OF THE CABLES FROM FALLING INTO THE
TAILCONE.
2. Remove the two aft most belly inspection covers.

3. Remove the Lock Clips from one of the cable tensioners. Locking clips are one
use only. Clips must be discarded after removal.
4. Rotate the tensioning barrel to slacken the stabilator control cables.
5. Disconnect the stabilator control cables.
6. Disconnect the aft end of the Trim/Servo Pushrod from the Anti-servo Tabs.
7. Remove the two bolts attaching the counter balance arm to the stabilator.
8. Remove the two bolts attaching the stabilator to the aft end of the tail cone.
9. Remove the stabilator assembly. Note: while extracting the counter balance arm
from the fuselage, rotate the counter balance arm 90 degrees to allow it to pass
through the aft tailcone bulkhead.
Bearing Replacement
10. Pressing out the bearing: Position the sockets on each side of the bearing then
use the nut, washer and bolt inserted through both sockets and the bearing. Tighten
the nut on the bolt to press the bearing towards the large socket. See Figure 16.

Figure 16: Extracting the DW4K2X bearing
11. Carefully clean the new bearing and the inner bore of the VA-146A Flange
Housing using denatured alcohol. After cleaning, handle the bearings with care as to
not re-contaminate the outer surface.
12. Insert a bearing into the VA-146A Flange Housing with minimal engagement just
far enough that the bearing aligns itself with the center hole in the flange.
13. Place a bead of Loctite 648 onto the outer surface of the bearing around the
entire circumference next to the edge of the VA-146A Flange Housing.
14. Pressing in the bearing: Using the same process as removing, use the small
socket to press the bearing towards the large socket and into the VA-146A Flange
Housing until the bearing is flush on both sides. Allow the Loctite sufficient time to
cure per instructions on the package.
15. After reinstalling the stabilator readjust the stabilator control cable tensions in
accordance with the KAI and install new lock clips on the adjuster barrel.
■ CAUTION: BE SURE TO RE-ORIENT THE COUNTERBALANCE ARM SO THAT THE

COUNTERBALANCE WEIGHT IS POSITIONED CORRECTLY. REFER TO KAI

MAIN GEAR REMOVAL

Expendable Hydraulic fluid
Replaceable Left Main Gear Leg
Right Main Gear Leg
Outbd. Main Gear Attach Brkt
Outbd. Wear Plate
Inbd. Main Gear Attach Brkt
Inbd. Wear Plate and Spacer
Service Rating Line
Matco or Grove Wheel user
manual
2. Remove the two outboard center section Cover Plates on the belly. (3-4)
3. Drain the hydraulic fluid. (7-5)
4. Disconnect the brake line at the main gear attach bracket.
5. Remove the center bolt, washer, and nut from the inboard main gear attach
bracket.
6. Loosen the remaining inboard and outboard attach bracket hardware.
7. Remove the main gear-leg.
INSTALLATION
2. Add hydraulic fluid and bleed the brake system.
3. Torque all landing gear attach hardware. Remember to account for
prevailing torque.
NOSE GEAR REMOVAL

Replaceable Nose Gear leg
Service Rating Line
1. Remove the top and bottom cowl. (3-4)

2. Lift and support the aircraft. Add an additional support under the aft end of the tail
cone to stop the aircraft from tipping back when the engine is lifted (1-16)
▲ WARNING: DO NOT REMOVE THE UPPER VIBRATION-ISOLATOR BOLTS.
3. Use an engine hoist to support the engine weight, by slinging at the engine
mount directly behind the aft top of the engine case.

4. Remove the lower engine vibration-isolator bolts (2).

5. Remove the nose gear-leg to fuselage attach bolts (13), and washers (13).
● NOTE: THE ENGINE CAN BE LIFTED BY HAND AT THE GEARBOX.
6. Lift the front of the engine only enough to remove the engine weight from the
gear-leg bracket.
7. Remove the nose gear-leg.
INSTALLATION
1. Lift the front of the engine only enough to provide room behind the engine mount
for the nose gear-leg.
2. Install the nose gear-leg and attach hardware.
3. Install the lower engine vibration isolator bolts.
BELT AND HARNESS REPLACEMENT

Expendable None
Replaceable Occupant Harness
Service Rating Line
Minimum Certification Owner and SPC, LSA-
RM, or A&P
▲ WARNING: HARNESS PARTS THAT SHOW ANY SIGN OF WEAR REQUIRE THAT THE
ENTIRE HARNESS SET BE REPLACED IMMEDIATELY.
1. Remove the seat ramp cover by sliding it outboard from under the center console
flange. (3-4)
2. Remove the crotch strap; bolt, bushing, washer, nut.
3. Remove each waist strap (2); bolt, bushing, washer, nut.
4. Remove the shoulder straps; bolt, bushing, washer, nut.
5. Install the new harness set and attach hardware.
CANOPY LATCH BLOCK REPLACEMENT

Expendable None
Replaceable Latch Block
Service Rating Line
1. Remove the latch block attach screws (3), shims (in installed), and the latch
block.
2. Install the new latch block and attach hardware in same orientation as when
removed.

STEP REPLACEMENT
Expendable Fuel tank sealant
Replaceable Left or Right Step
Service Rating Line
Minimum Certification Owner, LSA-RM, or A&P
1. Remove the step attach bolts (2), washers (2) and the step.
2. Install the new step and attach hardware.
3. Seal the gap between the step and the fuselage skin around the entire perimeter
with fuel tank sealant.
REAR SPAR DOUBLER REPLACEMENT

Special Tools #30 drill bit, drill, clecos, rivet
puller, rivet squeezer & dies
Expendable Fine file
Replaceable Left or Rt. Rear Spar Doubler
Service Rating Line
1. Based on the measurement from Section 3 Inspection, choose one of the
replacement W-1207B-x rear spar doublers. There are four different parts
available, ranging from 0.025 to 0.055 longer than the original, in increments of
0.010 — (i.e.: W-1207B-25 is 0.025” longer than stock.) Note that a pattern of
holes punched in the inboard end indicates the size – one extra hole is the first
oversize then two, three and four holes are used to identify each progressively
longer part.
2. Prepare the doubler by filing the rounded end just enough to remove the rough
surface left from manufacture, no more.
3. Prime the doubler if/as desired.
4. Remove the wing and remove the rivets attaching the W-1207B rear spar
doubler, W-1212 and hinge assembly to the rear spar. See KAI Section 5.4.

5. Final drill the holes in the new doubler to #30 (except the identifier holes) and
cleco it to the rear spar.
6. Test fit the wing with the new doubler clecoed in place (the hinge assembly does
not need to be in place for this step.) If the fit is too tight to allow normal Spar Pin
insertion, remove the wing, un-cleco the doubler and file the contour of the curve
to reduce its profile by a few thousandths of an inch and test fit again.
Note: When reducing the length, the primary material removal will be on
the inboard end (tip), and reducing the amount around the radius so that no
material is removed from the top or bottom. Repeat until the correct fit is
achieved.
7. Rivet the doubler and hinge assembly to the spar as shown below
Figure 16.1: Rear Spar Doubler Replacement

SERVICE SCHEDULE PROCEDURES
WING ATTACH LOCATION LUBRICATION

(WINGS REMOVED)
Expendable Wheel bearing grease
Anti-seize compound
Silicone Grease
Replaceable Fuselage Pin
AOA Connector Tube
Service Rating Line
FUSELAGE PINS
1. Wipe clean, the fuselage pins (2).
2. Wipe clean, the wing retention pin bushings (8).
3. Apply grease lubricant sparingly to the shaft of each fuselage pin.
STUB SPAR AND REAR SPAR

1. Wipe clean, the inboard end of the stub spar and rear spar of each wing. (5-4)
2. Apply anti-seize compound sparingly to the inboard end of the stub spar and rear
spar of each wing.
AOA ALUMINUM CONNECTOR TUBE

1. Wipe clean and apply a thin coating of silicone grease (avoid getting any grease
in the interior of the tube (5-4)
FLAPERON CONTROL CONNECTION LUBRICATION

(WINGS REMOVED)
Replaceable None
Service Rating Line
Wing removal (5-13)
1. Wipe clean, the UHMW pivot guide and actuation bracket of each flaperon. See
page 5-4, Figure 10.
2. Apply lubricant sparingly to the UHMW pivot guide and actuation bracket of each
flaperon.

FLAPERON BEARINGS LUBRICATION

Expendable Spray lubricant
Replaceable None
Service Rating Line
Flaperon hinge replacement (5-17)
1. Wipe away any dirt accumulation from each of the flaperon bearings (3).
2. Apply lubricant sparingly to each of the flaperon bearings.
3. Allow lubrication to penetrate while moving the Flaperon a few times through its
range of travel. Wipe away excess.
ANTI-SERVO TAB ATTACH HINGE LUBRICATION

Replaceable None
Service Rating Line
Minimum Certification Owner and SPC, LSA-RM, or
A&P
1. Lower the Anti-Servo Tab by adjusting the trim. Lower the trailing edge of the
stabilator.
2. Wipe away any dirt accumulation from the AST attach hinges.
3. Apply lubricant along the top of the left and right AST attach hinges.
4. Allow lubrication to penetrate for a minute. Wipe away excess.
NOSE WHEEL BEARINGS REPLACEMENT

■ CAUTION: THE NOSE WHEEL BEARINGS ARE NOT SERVICEABLE PARTS .
Special Tools Small wooden dowel, 1/2 - 1 inch dia.

Mallet
Expendable None
Replaceable Wheel bearings
Service Rating Line
Minimum Certification Owner, LSA-RM, or A&P
Additional References Matco user manual
2. Remove the nose wheel and tire assembly. (5-16)
4. Split the wheel and tire assembly by removing the bolts (3), washers (6), and
nuts (3).
5. Remove the wheel bearing from the inside of each wheel half using the dowel to

tap around its outer perimeter.

6. Press a new wheel-bearing into each wheel half by reversing the process.
7. Reassemble the wheel and tire assembly.
wheel rim. The final inflation pressure is 22 psi.
9. Install the wheel and tire assembly.
MAIN WHEEL BEARINGS LUBRICATION
Replaceable Wheel bearing
Service Rating Line
Additional References Matco or Grove Wheel user
manual
2. Remove the main wheel and tire assembly.
3. Remove and clean the main wheel bearings (2).
4. Apply wheel-bearing grease to each of the bearings.
5. Install the wheel-bearings.
6. Install the wheel and tire assembly and adjust as described in the appropriate
wheel user manual.
NOSE FORK PIVOT TENSION AND LUBRICATION
Special Tools Tensile weight scale
Expendable Waterproof wheel bearing grease
Scotchbrite pad
Fine sandpaper
Replaceable Nose fork bushings
Service Rating Line
2. Remove the nose fork cotter pin, nut, and spring washers (2) Note the specific
orientation of the Spring Washers.
3. Clean the end of the nose gear leg and the nose fork bushings. Inspect the stub
of the gear leg for rust/corrosion and remove if noted.
4. Apply a liberal amount of marine trailer (or waterproof equivalent) wheel bearing
grease to the nose fork bushings and stub of the nose gear leg.
6. Tighten the nut until a push or pull force of 18-20 lbs applied at the axle is
measured while the nose fork is rotating around the end of the nose gear leg.

WHEEL ASSEMBLY BALANCING PROCEDURE
● NOTE: IT IS NOT A MAINTENANCE REQUIREMENT THAT THE NOSE OR MAIN

WHEEL/TIRE ASSEMBLIES ON THE RV-12IS BE BALANCED BECAUSE OF THE
RELATIVELY LOW TAKEOFF AND LANDING SPEED. SHOULD A VIBRATION BE DETECTED
THAT IS SUSPECTED TO BE CAUSED BY A WHEEL/TIRE IMBALANCE, THIS PROCEDURE
MAY BE USED.
1. Remove the suspected out of balance wheel/tire assembly(s) from the aircraft.
2. Mount the Wheel/Tire assy. in a static balance test stand and allow the assy. to
rotate to the heavy side down position.
3. A.) Main Wheel assy. - Use tape to temporarily add stick on wheel weights
(obtain from a local automotive store commonly available wheel weights with
self-adhesive) to the outboard wheel flange, opposite the heavy point of the
wheel, until the assy. can be moved to any rotational position without it rotating.
Mark the position of the wheel weights and then remove them. Thoroughly clean
the area of the wheel flange where the wheel weights will be located. Remove
the protective backing and press the wheel weights in place on the wheel flange.
B.) Nose Wheel assy. - Use tape to temporarily add stick on wheel weights to the
interior area of the nose wheel (working through the lightening holes in the
wheel). If the proper weight location coincides with one of the three wheel
through bolts, distribute the weight, as close as possible, to each side of the
through bolt. Thoroughly clean the interior area of the wheel where the wheel
weights will be located. Remove the protective backing and press the wheel
weights in place on the interior area of the wheel.
4. Re-install the wheel assy. on the aircraft.


Chapter 6 - FLIGHT CONTROLS
Overview ......................................................................................................................................... 6-2

Components ............................................................................................................................. 6-2
Service ............................................................................................................................................. 6-3
Supplies .......................................................................................................................................... 6-3
Special Tools................................................................................................................................. 6-3
Expendable ................................................................................................................................... 6-3
Replaceable .................................................................................................................................. 6-3
General ............................................................................................................................................ 6-3
Stabilator pulley replacement and cable tension adjustment ......................................................... 6-3
Control cable replacement.............................................................................................................. 6-6
Rod end replacement ..................................................................................................................... 6-7
Bellcrank bearing replacement ....................................................................................................... 6-7
Rudder pedal removal .................................................................................................................... 6-8
Installation ................................................................................................................................... 6-8
Service Schedule Procedures .................................................................................................. 6-8
Control system rod end lubrication ................................................................................................. 6-8
Cable end hardware lubrication ..................................................................................................... 6-9

OVERVIEW
The flight control system enables the pilot to operate the control surfaces.
Forward or aft movements of the control stick control the pitch. The pitch control linkage
is a pair of cables, each routed around a pulley and attached to control horns on the
stabilator. The pitch-trim is controlled by a linear actuator influencing the length of the
anti-servo tab pushrod assembly, controlled by the pilot using a stick mounted switch or
optionally, by the autopilot. Side-to-side movements of the control stick controls roll via
push rods, a bell crank, and torque tubes. Rudder pedals control yaw via cables to the
rudder. The flaps function of the flaperons is activated by a linear actuator controlled by
a switch on the center console.
Refer to the KAI to identify the individual parts and part #’s of the control system.

processes.
COMPONENTS
1 Flap Handle Pushrod Refer to KAI
1 Flaperon Mixer Bellcrank F-1263A & F-1263B
2 Control stick pushrod Refer to KAI
2 Control stick WD-1212
2 Flaperon pushrod Refer to KAI
1 Left flaperon torque arm Refer to KAI
1 Right flaperon torque arm Refer to KAI
2 Stabilator cable F-01247C & E
2 Rudder cable F-01239-1
2 Rudder pedal WD-01206-1
2 Stab cable pulley MS24566-4B
4 Locking clips MS21256-1
1 Pitch / Trim servo See Chapter 8
Optional Components
1 Autopilot Module IF DYNON AP SV-AP-PANEL and SV-
KNOB-PANEL or Garmin GMC 507
1 Autopilot (Pitch) Servo IF DYNON AP SV32 or Garmin GSA 28
1 Autopilot (Roll) Servo IF DYNON AP SV32 or Garmin GSA 28

SERVICE
Annual lubrication will maximize the longevity of the control system. Refer to the
service schedule checklist for the specific service frequency of the components.
See Supplement for service schedule checklist.
SUPPLIES
i Cable tension meter i Cotter pins
i Spring clamps (3) i Safety wire
i Stick, 41" long i Spray lubricant
i MS21256-1 Lock Clips
REPLACEABLE
i Stabilator pulley
i Stabilator cables
i Rudder cables
i Bearing #DW4K2X (Bellcrank)
i Rod ends:
Control Stick: M3414 / CM-4MS
Flaperon: F3514M
Trim/Servo: MM-3
i Rudder pedal
GENERAL
STABILATOR PULLEY REPLACEMENT AND/OR CABLE TENSION
ADJUSTMENT
Special Tools Cable tension meter
Spring clamps (3)
Stick, 41" long
Expendable Cotter pins, MS21256-1
Lock Clips (4)
Replaceable Stabilator pulley
Service Rating Line
Additional References KAI Section 32
1. Remove the right seat ramp cover and baggage bulkhead corrugation. (3-4)

2. Remove the
stabilator
control cable
barrel lock
clips from one
barrel as
shown in
Figure 17.
Locking clips
are one use
only. Clips
must be
discarded after
removal.
Figure 17: Locking clip removal
3. Loosen the
tension of the
stabilator
cables by
turning the
tensioner
barrel as
shown in
Figure 18.
Figure 18: Tensioner barrel removal

4. Remove the pulley axle hardware and pulleys.
5. Capture the stabilator cables between the bushing and the new pulleys.
6. Install the pulley axle hardware.
7. Place a small weight on the stabilator to hold it trailing edge down. Remove the
slack from the upper cable by tightening the upper turnbuckle until the control
stick and stabilator just start to lift off the stops at about the same time when the
stick is moved aft.
Remove the slack from the other cable by adjusting the lower turnbuckle. Check
the entire length of the cables to ensure they are free from interference, are
properly aligned in the pulleys, and do not touch each other. Pull the stick aft to
make sure that the stabilator trailing edge moves up.

NOTE: Cable tension will change significantly with changing temperature.

The cable tensions given below are for an aircraft stabilized at a
temperature of 70O F.
8. Position one of the WD-1212 Control Sticks so that the top end is 10 inches from
the instrument panel. Secure the control stick in place using a spring clamp to
attach it to a 41" long stick bridged between and clamped to the upper longerons.
Check the cable tension just aft of the F-1207B Baggage Bulkhead using a
calibrated cable tension meter, making sure the control stick is still correctly
positioned.
Adjust turnbuckles an equal number of turns each to achieve 35-45 lbs of tension
with the groove in the cable ends aligned with a V-notch in each turnbuckle barrel
as shown in Figure 17. This tension will prevent the cables from "slapping"
against the tailcone bulkheads when the control sticks are moved suddenly and
repeatedly forward then aft.
9. Remove the clamp and stick from the control stick and the weight from the
stabilator.
Move the control stick between the forward and aft pitch stops. The stabilator
should reach its travel stops just before the corresponding control stick stops are
reached. If not, adjust the turnbuckles an equal and opposite number of turns
until this is achieved. (Example: If the stabilator reaches its T.E. up stop too soon
loosen the upper turnbuckle and tighten the lower turnbuckle. This will lengthen
the upper cable and shorten the lower cable). After making adjustments repeat
step 6 to reconfirm proper cable tension.
10. Once the proper tension is achieved, and no more than three threads are
exposed from the ends of the barrels, align the V-notch in the ends of the barrel
with the groove in the cable ends and then insert the lock clips as shown in
Figure 17. The hook end of the lock clips are inserted into the hole in the center
of the barrel and must be completely pressed in until the hook springs open
inside the barrel.

CONTROL CABLE REPLACEMENT

■ CAUTION: THE CONTROL SURFACE WILL SWING FREELY WHEN THE CONTROL
CABLES ARE REMOVED.
● NOTE: ALWAYS REPLACE CONTROL CABLES AS A SET.
Special Tools String

Cable tension meter
Spring clamps (3)
Stick, 41" long
Lock Clips
Replaceable Stabilator cables
Rudder cables
Service Rating Line
1. Remove the seat ramp cover, baggage bulkhead corrugation, upper tail cone
fairing, lower tail cone fairing, (3-4)
2. For rudder cable, remove the rudder cable sleeve attach hardware; screws (3),
washers (3), nuts (3) (located beneath seat ramp cover.
3. For the stabilator cable, remove the stabilator pulleys. (6-4)
● NOTE: TIE A STRING, LONGER THAN THE CONTROL CABLE, TO THE FWD END OF
THE CONTROL CABLE AND WRAP THE SAME END OF THE CONTROL CABLE WITH A
PIECE OF TAPE TO AVOID BULKHEAD DAMAGE.
4. Disconnect the attach hardware (see below) at the forward and aft end of the
cable to be removed.
Rudder cable end hardware:
Fwd; bolt, washer, nut, and cotter pin.
Aft; bolt, washers (3), nut, and cotter pin.
Stabilator cable end hardware:
Fwd; bolt, washer (2), nut, and cotter pin.
Aft; bolt, washers (3), nut, and cotter pin.
5. Pull the cable out from the opposite end of the string. Remove the cable, leaving
the string in its place.
6. Tie the new cable to the end of the string and cover the end with a piece of tape.
7. Installation procedure is reverse of the removal procedure, using the string to pull
the cable through the fuselage.
8. Adjust cable tension as described earlier in this chapter.

ROD END REPLACEMENT

Replaceable Applicable rod end
Service Rating Line
1. Remove applicable combination of the seat ramp cover, Center console and,
baggage cover
2. Remove the control rod attach hardware from the rod end for replacement;
Control stick – control stick pushrod: bolt, washers (3), and nut.
Control stick pushrod – bellcrank: washer and nut.
Bellcrank – Flap handle pushrod: bolt, washer and nut.
Flap crank assembly—bellcrank: bolt and washers (2)
Flaperon pushrod – flaperon torque arm: bolt, washers (2) and nut.
3. Make note of the number of threads exposed on the rod end shaft and the
clocking of the bearing body.
4. Remove the rod end and jam nut.
5. Add a jam nut to the new rod end shaft.
6. Install the new rod end to the position (from step 3) of the original rod end.
7. Install the control rod and control rod attach hardware.
BELLCRANK BEARING REPLACEMENT

Tools 1/4 drive socket slightly less than
5/8in in diameter. (A common
standard 7/16 socket generally
works.)
3/8 drive, 3/4 socket
Hex Bolt 1/4 diameter 3 inches long
(must be threaded at least 50% of its
length)
1/4 Flat Washer(2) and Hex Nut
Expendable None
Replaceable Bearing DW4K2X
Service Rating Line
1. Remove the aft center console. (3-4)

2. Remove the pushrod-to-bellcrank hardware:
Control stick pushrod: washer and nut
Bellcrank pivot bolt: bolt, washers (2)
Flaperon pushrod: bolt, washer and nut
3. Remove the bellcrank.
4. Use the same method instructed for extracting the DW4K2X hinge bearing on

page 5-20, Figure 16.

RUDDER PEDAL REMOVAL

Replaceable Rudder pedal
Service Rating Line
Matco user manual
1. Remove the fwd. tunnel side covers. (3-4)
2. Remove the rudder pedal access cover (directly aft of the horizontal tubes of the
rudder pedals) and hardware; screws (10)
● NOTE: THE MASTER CYLINDERS CAN BE REMOVED WITHOUT DISCONNECTING THE

BRAKE LINES.
3. Label, and then remove the master cylinders (4) from the rudder pedals. (7-3)
4. Remove the rudder cable hardware from each rudder cable; cotter pin, bolt,
washers (3) and nut.
5. Remove the rudder pedal-block hardware; bolts (2) and washers (2), from each
of the rudder pedal-blocks (3).
6. Remove rudder pedal assembly.
INSTALLATION
CONTROL SYSTEM ROD END LUBRICATION

Replaceable None
Service Rating Line
1. Remove the seat ramp covers, aft center console, and aft baggage floor cover.
(3-4)

2. Apply lubricant sparingly to the rod-end bearings on each end of the following
components:
i Flap handle pushrod
i Control stick pushrod
i Flaperon pushrod
i Trim / Servo pushrod
3. Allow lubrication to penetrate then wipe away excess.
CABLE END HARDWARE LUBRICATION

Replaceable None
Service Rating Line
1. Remove the fwd. tunnel side covers, right seat ramp cover, upper tailcone fairing,
and lower tailcone fairing. (3-4)
2. Apply lubricant sparingly to the hardware at both ends of the rudder and
stabilator control cables.


Chapter 7 - BRAKE SYSTEM
OVERVIEW .................................................................................................................. 7-2

Components........................................................................................................... 7-2
SERVICE ..................................................................................................................... 7-2
Supplies ................................................................................................................. 7-3
Special Tools ..................................................................................................................................................7-3
Expendable.....................................................................................................................................................7-3
Replaceable....................................................................................................................................................7-3
General .................................................................................................................. 7-3
Master cylinder removal..................................................................................................................................7-3
Removal ......................................................................................................................................................7-3
Disconnection..............................................................................................................................................7-3
Installation ...................................................................................................................................................7-4
Service Schedule Procedures ................................................................................ 7-4
Brake pedal torque tube lubrication ................................................................................................................7-4
Hydraulic fluid drain, flush, and replace ..........................................................................................................7-5
Draining.......................................................................................................................................................7-5
Flushing.......................................................................................................................................................7-5
Replacing ....................................................................................................................................................7-5
Brake lining replacement ................................................................................................................................7-6

OVERVIEW
The brake system includes the necessary components to provide directional
control and stopping ability while taxiing. The left and right brakes are independently
controlled hydraulic disc brakes. The fluid reservoir supplies the master cylinders with
hydraulic fluid. Pressure applied to either brake pedal causes the master cylinder to
force hydraulic fluid through the plastic and aluminum lines to the corresponding brake
caliper.
The RV-12iS can be equipped with Wheel/Brake assemblies made by Matco or Grove.
The Matco wheel can be identified by a hub assembly that bolts to the wheel halves.
The Grove wheel assembly has integral hub halves on each wheel half like other
traditional light aircraft wheels.
Refer to the Matco or Grove manuals and the KAI to identify the individual parts of the
brake system.

repair processes.
COMPONENTS
2 Disc and caliper Refer to Matco or Grove manual
4 Brake lining plates Refer to Matco or Grove manual
4 Brake linings Refer to Matco or Grove manual
4 Brake pedal WD-1209
2-L,2-R Brake pedal torque tube WD-1211-L & R
2 Left brake master cylinder BRAKE MAST CYL LEFT-1
2 Right brake master cylinder BRAKE MAST CYL RIGHT-1
1 Fluid Reservoir VA-107
2 Aluminum Line Refer to KAI
6 Plastic Line Refer to KAI
SERVICE
Use of the proper hydraulic fluid is necessary for proper operation of the brake
system. It is good practice to replace the hydraulic fluid every 5 years. If any indication
of contamination is present, replace hydraulic fluid as soon as possible. Since the
brakes on the RV-12iS are relied on for part of the airplanes steering control on the
ground, any detected leaks should be repaired prior to further flight. Refer to the service
schedule checklist for component service frequency.

SUPPLIES
■ CAUTION: USE ONLY MIL SPEC MIL-PRF-83282 (PREFERRED) OR MIL-H-
5606A HYDRAULIC FLUID! DO NOT USE AUTOMOTIVE BRAKE FLUID. DAMAGE TO O-
RING SEALS MAY RESULT.

i Brake bleeding fluid pump i Hydraulic fluid
i Container i Wheel bearing grease
i Cotter pins
i Brake linings
REPLACEABLE
i See component list on page 7-2.
GENERAL
MASTER CYLINDER REMOVAL

■ CAUTION: THE LEFT AND RIGHT MASTER CYLINDERS ON EACH SIDE OF THE
AIRCRAFT ARE NOT INTERCHANGABLE.

Cotter pins
Replaceable Left/Right Brake master
cylinder
Service Rating Line
Matco user manual
REMOVAL
1. Remove the upper and lower master cylinder attach hardware.
Upper: clevis pin, washer, and cotter pin.
Lower: bolt, washer, nut, and cotter pin.
DISCONNECTION
1. Drain the hydraulic fluid. (7-5)
2. Make note of the hose connections.
3. Disconnect brake lines from master cylinder.

INSTALLATION
2. Bleed the brake system. (7-5)
BRAKE PEDAL TORQUE TUBE LUBRICATION

Wheel bearing grease
Replaceable None
Service Rating Line
● NOTE: SERVICE ONE PEDAL AT A TIME.
1. Actuate the rudder

pedals so that the
brake pedal to be
serviced is offset
from the adjacent
rudder and brake
pedal. The
following steps
relate to Figure 19.
2. Remove the
master cylinder
lower hardware.
3. Remove the WD-
1209 brake pedal
hardware; bolt,
washer, and nut.
Figure 19: Torque tube lubrication

4. Remove the brake pedal block from the brake pedal.

5. Remove the WD-1209 brake pedal from the rudder pedal.
6. Clean the pivot tube then apply grease to the exterior of the tube.
HYDRAULIC FLUID DRAIN, FLUSH, AND REPLACE

Replaceable None
Service Rating Line
Matco user manual
DRAINING
1. Place suitable containers beneath each brake caliper to capture hydraulic fluid
from each bleeder valve.
2. Open the bleeder valve on each brake caliper and allow fluid to drain.
FLUSHING / REPLACING
1. Install a clear hose on the top of the brake fluid reservoir and insert it in a
container to catch fluid overflow.
2. Attach a pump style oil can filled with hydraulic fluid to the bleeder valve on the
bottom of one of the brake calipers. Open the bleeder valve and pump the oil
can until clean fluid flows in the clear tube at the top of the fluid reservoir. Close
the bleeder valve and remove the oil can and hose.
3. Repeat the previous step on the other brake caliper.
4. Confirm that the brake pedal at each seat position for the left and right brake
systems feel firm with no sponginess when pressed. Also confirm that there are
no air bubbles visible in the translucent brake lines between the left and right
seat rudder pedals. If there is any sponginess or presence of air bubbles repeat
the flushing / replacing steps.
5. Use a syringe to slightly reduce the fluid level in the reservoir and reinstall the
reservoir cap.

BRAKE LINING REPLACEMENT

● NOTE: IT IS RECOMMENDED TO REPLACE ALL OF THE BRAKE LININGS ON BOTH
SIDES EVEN IF ONLY ONE LINING REQUIRES REPLACEMENT.
Expendable Brake linings

Safety wire
Replaceable Brake disc
Service Rating Line
Matco or Grove user
manual
1. Remove the 2 safety wired bolts and remove the stationary brake lining plate.
2. Remove the brake caliper from the brake mounting plate (use care to not
damage the aluminum brake line)
3. Remove the floating brake lining mounting plate.
4. Check that the brake disc is within thickness wear limits. Replace if necessary.
5. Install new linings on the brake mounting plates per Matco or Grove instructions.
6. Install the floating brake mounting plate on the brake caliper.
7. Install the brake caliper on the brake mount plate.
8. Install the stationary brake lining mount plate and safety wire the bolts.
● CAUTION: UNTIL THE BRAKE LINING CONDITIONING PROCEDURE HAS BEEN

COMPLETED, BRAKE EFFECTIVENESS CAN BE SEVERELY REDUCED WHICH WILL
NEGATIVELY EFFECT STEERING ABILITY AND WILL GREATLY IMPACT THE STOPPING
DISTANCE
9. Complete the brake lining condition procedure as specified in the Matco or Grove
user manual.
10. Test for proper brake system operation. Check the hydraulic fluid level.

Chapter 8 - ELECTRICAL SYSTEM
OVERVIEW .................................................................................................................. 8-2

Components........................................................................................................... 8-2
Optional Lighting .................................................................................................... 8-3
Optional Components............................................................................................. 8-3
SERVICE ..................................................................................................................... 8-4
Supplies ................................................................................................................. 8-4
Special Tools ..................................................................................................................................................8-4
Expendable.....................................................................................................................................................8-4
Replaceable....................................................................................................................................................8-4
General .................................................................................................................. 8-5
Battery removal ..............................................................................................................................................8-5
Installation ...................................................................................................................................................8-5
Fuse replacement...........................................................................................................................................8-6
Pitch-trim servo replacement ..........................................................................................................................8-7
Electrical component replacement..................................................................................................................8-8
Wire repair ......................................................................................................................................................8-9
Wire replacement ...........................................................................................................................................8-9
Snap bushing replacement ...........................................................................................................................8-11
Service Schedule Procedures .............................................................................. 8-12
Battery recharge ...........................................................................................................................................8-12

● NOTE: FOR A SCHEMATIC OF THE ELECTRICAL SYSTEM REFER TO THE POH OR GO TO

THE DOWNLOADS PAGE AT WWW.VANSAIRCRAFT.COM
OVERVIEW
▲ WARNING: THE RV-12IS (ULS) FUSE MODULE IS NOT SERVICEABLE. SERIOUS
RISK OF ELECTRIC SHOCK REMAINS AFTER THE POWER SUPPLY IS REMOVED .
The RV-12iS electrical system is a 12 VDC, negative ground system equipped

with either an EarthX Lithium (LiFePO4) (iS) or Odyssey lead/acid dry cell (ULS) style
battery mounted on the forward right side of the firewall. The generator operates only
while the engine is running. The generator supplies power to the regulator, which serves
the primary aircraft power system and charges the battery. The primary aircraft power is
a 30 amp fused circuit. Lights, servos, fans, avionics, and control switches are all fused
secondary circuits and part of the primary circuit.

repair processes.
COMPONENTS
1 Battery EarthX ETX900(iS) or ES PC680(ULS)
12 Blade Fuse ATO/ATC ¼ “ blade style 1, 2, 3, 5, 7.5,
30 Amp rating. All fuse values of 3
amp and higher are required to have
LED “blown fuse” indicators.
1 Stall Warning switch ES E22-50K
2 Fuselage pin switch ES E22-50K
1 Pitch-Trim servo ES MSTS-B6-7T-165
2 Cooling Fan ES CPU FAN
1 12V Power Outlet ES AS212
1 Master relay ES 24115
16 Wing Connector (wing-to-fuse) ES-00077, ES-00078
1 Starter Refer to Rotax Manual
1 Regulator Refer to Rotax Manual
1 Ignition A Refer to Rotax Manual
1 Ignition B Refer to Rotax Manual
1 Starter relay Refer to Rotax Manual

OPTIONAL LIGHTING
The lighting components include the wing tip light assembly, extension, landing
light rib, landing light, lens backing strip, landing light lens and red eyeball cockpit light.
See Figure 20. The wing tip light mounts in the extension which attaches to the wing tip.
The landing light is mounted to the landing light rib which is attached inside the wing
skin. The eyeball light mounts to the rollover structure.
Figure 20: Optional Wing Tip Lighting (eyeball light not shown)
OPTIONAL COMPONENTS
1 Lighting See shaded items below & Refer to KAI
1 Wing Tip NAV/Position/ LN-200-1 (green light shown)
Strobe Light Set
2 Extension W-1222-L and W-1222-R
1 Lens Backing Strip W-1223E
1 Landing Light LL-200
1 Landing Light Lens W-00014 (Lens Only)
Not Shown See shaded items below & Refer to KAI
1 Landing Light Rib W-1223B
1 Red Eyeball Cockpit Light LC ECL-02

SERVICE
▲WARNING: ALWAYS HAVE AN APPROPRIATE FIRE EXTINGUISHER READILY AVAILABLE.
▲WARNING: BEFORE PERFORMING ANY MAINTENANCE OR REPAIRS TURN THE MASTER
SWITCH 'OFF' AND DISCONNECT THE NEGATIVE (-) BATTERY CABLE FROM THE BATTERY.
■ CAUTION: REPLACEMENT COMPONENTS, WIRE, TERMINALS, AND FUSES MUST BE OF

THE SAME TYPE AND RATING AS THE ORIGINAL PARTS.
There are no serviceable electrical components. Replace malfunctioning or failed

components. Electrical components that are omitted from the component list on page 8-
2 are not considered line maintenance.
SUPPLIES
TOOLS EXPENDABLE
i Battery charger i Wire terminals:
i Wire terminal crimping tool Splice
i Wire cutter Spade (male/female)
i Multi-meter Ring
i Razor knife
REPLACEABLE
i See component list on page 8-2.
i Wire (gauge = original)
i Snap bushing (size = original)

GENERAL
BATTERY REMOVAL
Expendable None
Replaceable Battery
Service Rating Line
Minimum Certification Owner and SPC, LSA-RM or
A&P
Additional References EarthX or Odyssey owner’s
manual
1. Remove the top cowl. (12-4)

2. Remove the negative (-) battery cable.
3. Remove the positive (+) battery cable.
4. Remove the battery box angle.
5. Lift the battery to remove.
INSTALLATION

FUSE REPLACEMENT
■ CAUTION: BLOWN FUSES MUST BE REPLACED ONLY WITH FUSES OF THE SAME TYPE
AND RATING AS SPECIFIED BY THE MANUFACTURER.
■ CAUTION: THE MASTER SWITCH MUST BE IN THE ‘OFF’ POSITION BEFORE
REPLACING ANY FUSE.
● NOTE: REPLACEMENT FUSES FOR ANY CIRCUIT IN WHICH A 5 AMP FUSE OR
LARGER IS SPECIFIED MUST BE OF THE TYPE THAT ILLUMINATE WHEN BLOWN .
Good Fuse Blown Fuse
1. Remove the suspected blown

fuse.
2. Perform visual inspection and/or
use multi-meter to test fuse.
3. Insert new fuse with proper
rating as shown in Figure 21.
4. A recurring blown fuse indicates
excessive current draw from the
corresponding circuit of the
electrical system. See Chapter
18.
SkyView/ G3X
( iS )
Figure 21: Fuse panel

PITCH-TRIM SERVO REPLACEMENT

Special Tools D-sub pin extractor
Expendable None
Replaceable Pitch-Trim servo
Service Rating Line
REMOVAL
1. Disconnect the negative (-) battery cable.

3. Disconnect the pitch-trim servo D-sub connector. Detach the servo connector
half from the servo tray.
4. Disconnect the trim servo from the AST assembly by removing the bolt, washers
(3) and nut.
5. Remove the trim servo from the servo tray by removing the screws (4), washers
(4), and nuts (4).
6. Remove the 5 wires from the d-sub connector using a pin extractor.
7. Take note of the position of the clevis and jam nut on the servo shaft and then
remove them from the servo.
INSTALLATION
1. Thread the jam nut onto the new pitch-trim servo shaft until it contacts the pitch
trim servo shaft housing. Thread the pitch-trim servo shaft onto the clevis rod end
on the pushrod assembly until it contacts the jam nut. Back the pitch-trim servo
off two full turns. Tighten the jam nut against the pushrod assembly.
2. Insert the wire pins on the new servo into the appropriate pin locations on the d-
sub connector (Refer to KAI Section 11).
3. Install the servo on the servo tray by reversing the process used for removal.
4. Switch on the master switch and verify that when the pitch trim is activated in the
nose down direction, the antiservo tab assembly moves up. If the AST moves in
the wrong direction, double check that the servo wires were inserted into the
correct connector pin locations.
5. Confirm proper movement of the pitch trim indicator. If incorrect, double check
the wiring on the connector.

ELECTRICAL COMPONENT REPLACEMENT

Special Tools Wire cutter

Terminal crimping tool
Expendable Wire terminals
Replaceable See component list. (8-2)
Service Rating Line
1. Disconnect negative (-) ground wire.

2. Remove the applicable access covers to expose the failed component (3-4)
3. Label the wires. Disconnect the wire(s) from the failed component.
4. Make note of the hardware configuration.
5. Disconnect the mechanical connection, if applicable.
6. Remove the hardware that secures the component and remove the component.
7. Install a new component, new gaskets (if applicable), and hardware of the same
type.
8. Re-attach applicable electrical and mechanical connections.
9. Reconnect the negative (-) battery cable.

WIRE REPAIR
Wire stripper
Wire terminal crimper
Multi-meter
Replaceable Wire
Service Rating Line
Additional References ASTM F39 F2639
■ CAUTION: THE REPLACEMENT WIRE SIZE AND TYPE MUST BE EQUAL TO THE ORIGINAL.
1. Remove the entire damaged section of the wire.

2. Rectify the issue that caused damage to the original wire (sharp edge, chaffing,
heat, etc).
3. Route the new length of wire along the same path as the original wire.
4. Use aircraft grade wire terminals to connect the new wire in place of the original
wire.
5. Test the continuity of the wire to ensure a complete connection.
6. Test the operation of the electrical system.
WIRE REPLACEMENT
Wire stripper
Multi-meter
Replaceable Wire
Service Rating Line
Additional References ASTM F39 F2639
■ CAUTION: THE REPLACEMENT WIRE SIZE AND TYPE MUST BE EQUAL TO THE ORIGINAL.
1. Bypass the existing wire with a new wire of equal length.

2. Install new terminals on the new wire that are the same type as those on the
existing wire.
3. Connect the new wire terminals to the terminals that are connected by the
existing wire.
4. Check the continuity of the replacement wire.
5. Test the operation of the component that is connected by the replacement wire
and test the operation of the entire electrical system.

SNAP BUSHING REPLACEMENT

Special Tools Razor knife
Expendable None
Replaceable Snap bushing
Service Rating Line
1. Extract the failed snap bushing by compressing the two locking tabs and
pushing it out of the mounting hole.
2. Cut the
new snap
bushing as
shown in
Figure 25.
The snap
bushing
should be
of the same
size and
type as the
original.
Figure 25: Snap Bushing
3. Flex open the bushing enough to insert the routed elements.

4. Snap the bushing into the corresponding hole.

■ CAUTION: THE EARTHX LITHIUM BATTERY (IF EQUIPED) REQUIRES A SPECIAL

BATTERY CHARGER. REFER TO EARTHX DUCUMENTATION FOR DETAILS.
Special Tools Battery charger (special type

required for EarthX battery)
Expendable None
Replaceable None
Service Rating Line
Additional References Odyssey or EarthX owner’s manual
Battery charger owner manual
BATTERY RECHARGE
1. Connect the battery charger per the battery charger manufacturer and battery
manufacture instructions.
2. For Rotax 912iS equipped aircraft if you wish to interface with the EFIS system
turn on the EMS Backup Battery Switch. If the main bus voltage rises above 13.7
volts (which is likely with a battery charger connected) the automatic Start Power
Button will no longer function (see FTS Section VI START POWER SOLID
STATE SWITCH).
3. Charge the battery per the battery manufacturer instructions.

Chapter 9 - INSTRUMENTS & AVIONICS
OVERVIEW .................................................................................................................. 9-2

Instruments and Avionics Components..............................................................................9-2
Optional Components ........................................................................................................9-3
PITOT & STATIC............................................................................................................ 9-3
Components ......................................................................................................................9-4
SERVICE ..................................................................................................................... 9-4
Supplies ................................................................................................................. 9-4
Special Tools .................................................................................................................9-4
Expendable....................................................................................................................9-4
Replaceable...................................................................................................................9-4
General .................................................................................................................... 9-5
Component replacement................................................................................................9-5
Pitot/Static and AOA component replacement ...............................................................9-5
Light replacement ..........................................................................................................9-6
Audio Input & Adjustment...............................................................................................9-7
Service Schedule Procedures .................................................................................. 9-7
Software updates...........................................................................................................9-7

OVERVIEW
The Dynon SkyView HDX or Garmin G3X EFIS (Electronic Flight Information
System) / EMS (Engine Monitoring System) replaces the traditional mechanical flight
information and engine monitoring instruments. For removal, installation, inspection, or
servicing of the avionics components refer to the manufacturer user manuals.
The pitot and static systems provide static and dynamic pressure sources for
flight data calculations. The static system ports are located on each side of the tailcone.
A flexible plastic tube from the right static port crosses the tailcone to a plastic tee and
joins the flexible plastic tube from the left port. From the tee, a flexible plastic tube
routes to either beneath the aft baggage floor cover (G3X) or the upper middle of the tail
cone (SkyView HDX).The pitot port is an aluminum tube located at the tip of the
propeller spinner cone that extends aft to an adapter block mounted to the engine. A
flexible plastic tube continues aft from the adapter block to the air data computer either
under the baggage floor cover or in the upper tail cone.
A port similar to that used for the static system is located in the left wing for use as an
Angle of Attack (AOA) sensor. It is connected to the EFIS system using a flexible
plastic line and a self-mating connector at the wing root. A leak check of the AOA
system must be done anytime the wing is removed and re-installed, if required. (3-16)

repair processes.
INSTRUMENTS & AVIONICS COMPONENTS

1 Dynon Skyview HDX System See Dynon Manual
1 Garmin G3X System See Garmin Manual
1 Garmin GTX 23 ES or SkyView SV- See Garmin Manual or
XPNDR-26X Dynon manual
1 GTR-200 or GTR-225 See Garmin Manual
1 Transponder Antenna AV-00012
1 Emergency Locator Transmitter AV-E-04
1 ELT Remote E-04.5
1 ELT Antenna E-04.8
1 VHF Comm Antenna AV AV-17
2 Static Port RIVET SD-42-BSLF
1 F Plastic tee 125 X 125 X 125 TEE
1 Pitot block FF-1201, UHMW
1 Pitot tube FF-1202, AT6-058X5/16
1 Pitot line tubing FF-1216
1 Static line tubing PT 1/4 OD POLYPROP. TUBE

OPTIONAL COMPONENTS
2 Autopilot Servo See Dynon or Garmin Manual
1 SV-AP-PANEL See Dynon Manual
1 SV-KNOB-PANEL See Dynon Manual
1 Garmin GMC 507 Autopilot Controller See Garmin Manual
1 Landing light See Aero LED Manual
2 Navigation / Strobe light See Aero LED Manual
1 Cockpit light LC ELC-01
1 SkyView HDX or G3X Dual EFIS / EMS See Dynon or Garmin Manual
1 AOA indicator system See Dynon or Garmin Manual
1 ADSB Antenna AV-00014
1 ADSB Dynon Unit SV-ADSB-472
1 ADSB Garmin Unit GDL 50R (ADSB) or,
GDL 51R (XM) or,
GDL 52R (ADSB/XM)
PITOT, STATIC & AOA

PITOT, STATIC & AOA COMPONENTS

2 Static Source Rivet SD-42-BSLF
1 F Plastic Tee 125 X 125 X 125 TEE
1 Pitot Block FF-1201, UHMW
1 Pitot Tube FF-1202, AT6-058X5/16
2 FLF-00012 AOA Fitting
1 FLF-00015 Tube Guide (without O-ring)
or FLF-00015-1 Tube Guide (with O-ring)
1 FLF-00016 Connector Tube
1 AOA Port Rivet SD-42-BSLF
SERVICE
▲WARNING: ALWAYS HAVE AN APPROPRIATE FIRE EXTINGUISHER READILY
AVAILABLE.
Software updates are often available online for the Skyview HDX and Garmin
G3X. The physical avionics components are not serviceable by the consumer unless
otherwise noted in the manufacturer user manuals. A manufacturer authorized repair
facility will perform diagnosis and service to the avionics components.
The Cockpit, Nav/Strobe and Landing lights have no user serviceable parts.
Check the supply voltage and circuit connections. Replace the inoperable light if
necessary.
SUPPLIES
i Wire cutter i Wire terminals
i Wire terminal crimper i Plastic Tie Wraps
i Wire Stripper
Computer with internet
i
i USB Flash Drive / Memory Stick
REPLACEABLE
i Razor Knife i See component list on page 9-2.

GENERAL
COMPONENT REPLACEMENT
See 9-2 through 9-4.
COMPONENT REMOVAL BY OWNER/OPERATOR

Using the KAI as a guide, owner/operators are authorized to remove a screen or any
electrical component that is to be sent in for service.
PITOT / STATIC AND AOA SYSTEM COMPONENT REPLACEMENT

Special Tools Razor Knife
Wire cutter
Expendable Plastic tie wraps
Replaceable Connector
Tubing
Service Rating Line
REMOVAL
1. Make note of routing, location and orientation of the component to replace.
2. Remove the failing component.
INSTALLATION
1. Install a new component of equivalent properties and secure with plastic tie
wraps.
2. Complete the Pitot /Static and/or AOA check as outlined in the RV-12iS
production acceptance test document and Pitot/Static certification check (if
applicable) by 14 CFR 91.413

LIGHT REPLACEMENT

Wire Stripper
Replaceable Light Module
Service Rating Line
Minimum Certification Owner and SPC, LSA-RM or A&P
REMOVAL
1. Remove the light and fastening hardware;
Cockpit light: screws (3)
Landing light: screws (6), bolts (2)
Navigation light: Allen screw (1)
2. Label the wires that will be disconnected.
3. Unplug the wire terminals nearest to the light.
INSTALLATION
1. Install mating wire terminals on the replacement light.
2. Plug the light into the electrical system.
3. Install the new light and hardware.

AUDIO INPUT & ADJUSTMENT

All audio levels are set at the factory to default settings for audio balance. Audio volume
levels may need adjustment following component replacement. Following is a list of
signals and the corresponding adjustment within the component. (Example: Stall
Warning tone level is controlled by the GTR200 “AUX 1” input level.)
GTR200 Input
Signal EFIS GMA245 Input Level
Level
Stall Warning AUX 1 AUX 1
Set-up
EFIS Warning AUX 2 ALERT 1
Menu
Music Level Music Level (no XM) ENTERTAINMENT 1 (XM Music)
NAV Audio 1 (VOR/ILS) NAV AUDIO 1
GTN Main Audio (Touch Clicks) ALERT 4 AUDIO
NOTE: Included in the EFIS Warnings are: AOA, traffic, terrain, oil pressure, airspeeds,
etc., which can be configured in the EFIS itself.
Within the EFIS Set-up Menu:

1. Check that the Stall Warning is louder than example AOA tones.
2. Check that AOA example tones are louder than example EFIS warnings.
3. Check that XM or Bluetooth music is not louder than Stall Warning, AOA tones or
EFIS warnings.


NOTE: THERE IS NO SCHEDULED MAINTENANCE OR SERVICE ON ANY OF THE AVIONICS
OR OPTIONAL EQUIPMENT OTHER THAN THE PERIODIC REPLACEMENT OF THE ELT UNIT
BATTERY. REFER TO THE ELT OWNERS MANUAL FOR THIS PROCEDURE. PERIODIC
CHECKS SHOULD BE MADE AT A MINIMUM OF EACH CONDITION INSPECTION TO
DETERMINE IF ANY SOFTWARE UPDATES HAVE BEEN ISSUED FOR THE EFIS/EMS OR
GPS.
SOFTWARE UPDATES
Special Tools Computer with internet access and
Unit connection cable
Expendable None
Replaceable None
Service Rating Line
Additional References F39
Refer to the applicable user manual for the instructions and website address.

Chapter 10 - UTILITY SYSTEMS
OVERVIEW ................................................................................................................ 10-2

HEAT ........................................................................................................................ 10-2
Components......................................................................................................... 10-3
VENTILATION ............................................................................................................. 10-3
Components......................................................................................................... 10-4
SERVICE ................................................................................................................... 10-4
Supplies ............................................................................................................... 10-4
Expendable...................................................................................................................................................10-4
General ................................................................................................................ 10-4
Vent door adjustment ...................................................................................................................................10-4

OVERVIEW
The aircraft utility systems are the systems that are not critical to flight. The heat
system enables the occupants to control the cockpit temperature at each seating
position with a push/pull cable. Hot air diverted from a heat muff on the exhaust system
muffler provides cockpit heat. Cabin ventilation air can be controlled with either of the
two vents, one on each side of the fuselage.

repair processes.
HEAT
Air that passes through the heat muff plenum on the exhaust system muffler is
routed to a cockpit controllable valve on each lower corner of the firewall. A push / pull
cable on each valve controls a door to regulate the amount of air directed into the
cockpit.

HEAT COMPONENTS
1 Heat Muff Assy. FF-00090
2 Heat Control Valve Vent-00001 Assy.
3 Heat Muff Hose, 2” SCAT FF-00091
2 Push / Pull Cable CT A-740 BLACK
VENTILATION
A hand-operated vent on each side of the cockpit provides cockpit ventilation.

Each vent is a tip-out door installed on each fuselage side skin.

COMPONENTS
2 Vent brackets F-1086
2 Vent doubler F-1096
Vent door sub-assembly See shaded items below
2 Vent slide F-1087
2 Vent door doubler F-1092
2 Vent door F-1093
SERVICE
The heating and vent systems do not require regular maintenance. If the push /
pull cable’s operation is not smooth at any time, lubricate the interior of the cable with
spray lube.
The pre-flight and annual condition inspections are necessary to ensure all of the
components remain in good condition.
SUPPLIES
EXPENDABLE
i Spray lubricant
GENERAL
VENT DOOR ADJUSTMENT

Expendable None
Service Rating Line
Minimum Certification Owner with SPL, LSA-RM or A&P
No maintenance is required on either of the fresh-air vents. A damaged vent is

replaceable provided the fuselage skin is undamaged. The friction is adjusted using the
attachment screw and nut. Tightening the nut will increase the friction and loosening
will decrease it. Periodic adjustment may be required to provide enough friction that it
stays in the selected position in flight, but is easy to move by hand.

NONE


Chapter 11 - PROPELLER
Overview .................................................................................................................... 11-2

Components............................................................................................................... 11-2
SERVICE ...................................................................................................................... 11-2
Supplies ..................................................................................................................... 11-2
Special Tools ................................................................................................................................................11-2
Expendable...................................................................................................................................................11-2
Replaceable..................................................................................................................................................11-2
Spinner and Pitot Tube .............................................................................................................................. 11-3
Prop & Hub................................................................................................................. 11-3

OVERVIEW
The RV-12iS is equipped with a ground adjustable Sensenich propeller. For
instructions regarding adjust the propeller pitch, refer to the KAI and user manual
provided with the propeller.
The current propeller manuals and/or specifications take precedence over
referenced information in this manual. Current revisions to products or specifications
made by the propeller manufacturer will not be reflected in this manual.

repair processes.
COMPONENTS
1 Propeller, 2 Blade 2A0R5R70EN-V
1 Spinner cone, 2 Blade S-1201
1 Optional Propeller, 3 Blade 3Y0R5 C70MY
1 Optional Spinner Cone, 3 Blade S-01214
SERVICE
Brief instructions, referenced from the propeller manual, about caring for the prop
and hub are included below. For complete information, refer directly to the propeller
manual.
The spinner cone is constructed with a bushing for the Pitot tube. It has no
scheduled maintenance requirement other than regular inspection and replacement of
the bushing if excessive wear is detected.
SUPPLIES
TOOLS EXPENDABLE
i 7/16 diam. wood dowel i Notebook paper
REPLACEABLE
i Spinner cone
i Pitot tube bushing

SPINNER AND PITOT TUBE

Inspect the Pitot tube and bushing for excessive wear using a clearance gauge.
Make the clearance gauge by cutting a ¾ inch X 4 inch paper strip from common note
book paper (typical thickness is about .003 inch). Make a mark on the strip ¾ inch from
one end. Lay the paper strip lengthwise on the portion of the pitot tube that protrudes
out of the spinner with the marked end positioned nearest to the spinner. Wrap the
paper strip tightly around the radius of the pitot tube and attempt to insert it between
the pitot tube and the bushing. If the paper strip can be inserted to the marked ¾ inch
depth further inspection is needed.
Remove the spinner and inspect the portion of the pitot tube that turns within the
bushing for wear damage. If any is present the pitot tube and the bushing should be
replaced. To replace them see Section 47iS/U of the KAI.
If no wear damage is present on the pitot tube, just the bushing should be
replaced.
Remove the worn bushing by driving it out from the aft side of the spinner using a
7/16 in. diameter dowel. Install the new bushing per Section 47 of the KAI.
PROP & HUB

●NOTE: THERE IS NO SPECIFIED SERVICE LIFE FOR THE PROPELLER. HOWEVER IT IS
TO BE REMOVED FROM SERVICE WHEN IT NO LONGER MEETS THE CONTINUED
AIRWORTHINESS REQUIREMENTS SPECIFIED BY THE MANUFACTURER.
The following will aid in the safe operation, longevity and appearance of the propeller.
x Do not spin your propeller above the Propeller RPM Limits specified by the
manufacturer
x Check the hub clamping bolt torque after the first 5 hours and at each condition
inspection. Always check in the tightening direction.
x Before each flight carefully Inspect the propeller blades and hub for looseness, any
signs of damage, excessive wear or any other condition that would make the
propeller unsafe to operate.
x When the propeller is not in use position it horizontally. If it is exposed to weather
cover it with a weatherproof cover.
x Do not use the propeller as a tow-bar to move your aircraft.
x Apply a good quality automotive paste wax to the blades at least once a year. Avoid
liquid waxes.
x Avoid running-up in areas containing loose stones and gravel.
x Loss of surface finish from the leading edge is considered normal wear and is
dependent upon the amount of operation in rain and grit.
x Immediately following an impact of any kind remove the propeller from service until it

has been inspected and passed by qualified personnel.

x Whenever there is evidence of rough operation check for proper bolt torque. For new
installations it often helps to remove the propeller, rotate it 180˚ and reinstall.
x If vibrations are noticed or the pitch of the propeller has been changed, perform a
dynamic balance of the propeller according to the manufacturer’s instructions.
NOTE: A propeller that is significantly out of balance can affect the AHRS
accuracy and the lifetime of components in the aircraft.
x If the propeller shows any of the following signs of damage it must either be repaired
(if possible) or retired from service:
i Cracks in the metal hub or bolts
i Loose metal leading edge
i A crack across the blade
i A long or deep crack along the blade length
i Any portion of composite material missing
i Obvious damage or wear beyond economical repair

Chapter 12 - FIREWALL FORWARD
OVERVIEW ..................................................................................................................................................................12-2
Components..............................................................................................................................................................12-2
Engine......................................................................................................................................................................12-3
Rotax 912iS ..................................................................................................................................................12-3
Rotax 912ULS ..............................................................................................................................................12-3
Spark Plugs...............................................................................................................................................12-4
Ignition.......................................................................................................................................................12-4
SERVICE ...................................................................................................................................................................12-4
Supplies ............................................................................................................................................................12-4
Special Tools ................................................................................................................................................12-4
Expendable...................................................................................................................................................12-4
Replaceable..................................................................................................................................................12-4
General ....................................................................................................................................................................12-5
Cowling removal ...........................................................................................................................................12-5
Spark plug replacement................................................................................................................................12-5
Oil filter replacement.....................................................................................................................................12-6
Engine oil level check ...................................................................................................................................12-6
Engine coolant level check ...........................................................................................................................12-7
Air filter removal & installation ......................................................................................................................12-7
Carburetor Syncronization ............................................................................................................................12-8
Verify Functionality of Throttle Return Spring .............................................................................................12-10
Throttle Cable Lubrication & Replacement .................................................................................................12-10
Throttle Return Spring Replacement ..........................................................................................................12-11
Service Schedule Procedures ............................................................................................................................12-11
Cowl hinge pin lubrication...........................................................................................................................12-11
Oil Hose Replacement................................................................................................................................12-12
Cooling Hose Replacement ........................................................................................................................12-12
Manifold Pressure Hose Replacement .......................................................................................................12-13
Engine replacement....................................................................................................................................12-13

OVERVIEW
Engine information is taken from Rotax documentation. For complete engine
information refer to the Rotax engine documentation. Note: Rotax is the primary
authority for specifying the level of certification required by an individual
performing maintenance or repair on a Rotax 912ULS or 912iS engine. Refer to
the Rotax documentation to determine the qualifications or training required for
any maintenance or repair action.
The top and bottom engine cowling are a formed composite of fiberglass cloth
and epoxy-resin. The cowl is attached using screws and segments of piano hinge.
Hinge also joins the top and bottom cowl halves together. Adhesive heat shielding
protects the inner surface of the cowl. On the 912ULS engine, there is a cockpit-
mounted throttle and choke control. On the 912iS there is only a throttle control.

repair processes.
COMPONENTS
1 Rotax 912ULS Refer to Rotax documentation & See
Figure 26ULS.
1 Rotax 912iS Refer to Rotax documentation & See
Figure 26iS.
1 Engine mount WD-1220-PC
4 Vibration isolator EA 22002-15
4 Engine Mount Bushing Aluminum tube .376 X .528 X 1.9
ULS Engine controls See shaded items below
1 Throttle cable, 42” CT-01202
1 Dual Choke cable CT-01203
iS Engine controls See shaded item below
Cowling Shaded items below are iS only
1 Top cowl Cowl, 12iS Top
1 Bottom cowl Cowl, 12iS Bottom
1 Engine Air Duct Cowl-00006
1 Upper cowl hinge F-01201J-1
1 Upper cowl hinge F-01201K-1
2 Mid cowl hinge F-12116-1
2 Lwr cowl hinge F-12117-1
2 Cowl attach plate F-12130A
1 Cowl shield EA EXHST/COWL SHIELD

ENGINE
Figure 26iS: Rotax 912iS Sport
Figure 26ULS: Rotax 912ULS

Current engine product manuals and/or specifications take precedence over any

associated information referenced in this manual for convenience. This manual will not
reflect current revisions to products or specifications made by the engine manufacturer.
Refer to the engine manufacturer's operators manual for specifications.
SPARK PLUGS
Type: NGK DCPR8E
Socket: 5/8” spark plug
Electrode Gap: See Rotax Documentation
IGNITION
Dual Breakerless Capacitor Discharge
Firing Order: 1 - 4 - 2 - 3
SERVICE
Refer to the engine manual for full engine service details. The cowling does not
require regular maintenance. The cowl attach hinge pins may be lubricated with a dry
lubricant to ease removal and installation.
SUPPLIES
i Spark plug gap tool (wire type) i Spray lubricant
i Oil filter wrench i Engine coolant
i Engine oil
i Dry lubricant
i Oil filter
i Safety wire
i Cotter pins
REPLACEABLE
i Hinge pins
i Spark Plugs
i Vibration isolator
i Air filter
i Push/Pull cable

GENERAL
COWLING REMOVAL
Expendable None
Replaceable Hinge pins
Service Rating Line
Top Cowl:
1. Remove the screws (2) in the F-1240B Cover Plate located at the top rear of the
cowling to access the aft cowl attach hinge pins.
2. Remove the top cowl fwd. attach screws (6), side pin anchor screws (2), aft and
side hinge pins (4) and the top cowl.
Bottom Cowl:
1. Remove the bottom cowl attach screws (12) located on the bottom of the cowl.
2. (iS only) Remove the screws (4) that attach the air box filter plate to the engine
air duct.
3. Disconnect the SCAT hose from the inlet vent at the bottom left.
4. Remove the aft hinge pins (4), and remove the lower cowl by lowering it
(for the iS, the engine air duct should drop away from the air filter/plate).
INSTALLATION
SPARK PLUG REPLACEMENT OR RE-INSTALLATION

Special Tools 5/8” spark plug socket
Spark plug gap tool
Expendable Heat conduction compound
Replaceable Spark Plugs
Service Rating Line
Minimum Certification LSA-RM with Rotax Service
certification or A&P with Rotax
Service Certification.
Additional References Rotax 912 Line Maintenance manual
1. Refer to the Rotax manual.

OIL FILTER REPLACEMENT

Special Tools Oil filter wrench
Expendable Oil Filter
Replaceable None
Service Rating Line
Additional References Rotax 912 Line Maintenance manual
1. Refer to the Rotax manual.
ENGINE OIL LEVEL CHECK

▲ WARNING: BEFORE PERFORMING ANY INSPECTION OR SERVICE, ALLOW THE
ENGINE COMPONENTS TO COOL.
▲ WARNING: TURN OFF MASTER POWER AND BOTH IGNITION SWITCHES.
DISCONNECT THE NEGATIVE (-) GROUND WIRE TO THE BATTERY.
Expendable None
Replaceable None
Service Rating Line
Additional References Rotax 912 Operator Manual
1. Remove the oil tank cap.

2. Transfer oil from the crankcase to the oil tank by turning the propeller several
times by hand in the direction of normal engine rotation. Transfer is complete
when gurgling sounds come from the oil tank.
■ CAUTION: FOR LONG FLIGHTS REPLENISH OIL TO THE ‘MAX.’ MARK ON THE DIPSTICK.
● NOTE: THE QUANTITY DIFFERENCE BETWEEN ‘MAX.’ AND ‘MIN.’ MARKS ON OIL
DIPSTICK IS 0.45L (0.5 QUART).
3. Oil level must be between the ‘Max’ and ‘Min’ marks on the dipstick.

ENGINE COOLANT LEVEL CHECK

▲ WARNING: DO NOT REMOVE THE RADIATOR CAP FROM A HOT COOLING SYSTEM.
SCALDING COOLANT WILL SPRAY.
▲ WARNING: BEFORE PERFORMING ANY INSPECTION OR SERVICE, ALLOW THE
ENGINE COMPONENTS TO COOL.
Expendable Engine coolant

Replaceable None
Service Rating Line
Additional References Rotax 912 Operator Manual
1. Place a rag over the expansion tank cap.
2. Loosen cap to the first detent then step back for a few seconds.
3. Remove the expansion tank cap.
4. The expansion tank must be full of coolant.
5. Replace the cap.
6. The coolant level in the overflow bottle must be between the ‘Max’ and ‘Min’
marks.
AIR FILTER REMOVAL

Expendable None
Replaceable Air filter
Service Rating Line
Additional References Rotax 912 Line
Maintenance manual
1. Loosen the air filter clamp.
2. Remove the air filter.
INSTALLATION

CARBURETOR SYNCHRONIZATION (ULS)

Special Tools 1 - Vacuum gauge set
Expendable None
Replaceable None
Service Rating Line
Minimum Certification LSA-RM with Rotax Service
certification or A&P with Rotax Service
certification
Additional References Rotax Line Maintenance Manual
Refer to the Rotax Line Maintenance manual
● NOTE: WHEN CHECKING THE IDLE SPEED DURING THE ADJUSTMENT PROCEDURE
ONLY PULL LIGHTLY ON THE THROTTLE CONTROL UNTIL YOU JUST FEEL THE IDLE
STOPS ON THE CARBURETORS. A HEAVY PULL ON THE THROTTLE CONTROL WILL
FLEX THE THROTTLE ARMS AND GIVE AN INACCURATE IDLE SPEED.
● NOTE: IF THE THROTTLE HANDLE IS HELD FULLY AT IDLE FOR AN EXTENDED

PERIOD THE IDLE MAY CREEP DOWN TO APPROXIMATELY 1550 RPM. THIS IS
PERMISSIBLE WHEN SETTING UP THE CARBURETORS BUT DURING NORMAL GROUND
OPERATIONS THE IDLE SPEED SHOULD BE KEPT AT OR ABOVE 1650 RPM, OR
WHATEVER IDLE SPEED IS REQUIRED TO ALLOW THE ENGINE TO RUN SMOOTHLY.
OPERATING AT IDLE SPEEDS WHERE THE ENGINE IS MAKING A KNOCKING/RATTLE
TYPE NOISE WILL CAUSE GEARBOX DAMAGE.
● NOTE: OFTEN TIMES WARMING THE ENGINE BY RUNNING IT ON THE GROUND DOES
NOT QUITE BRING IT UP TO NORMAL OPERATING TEMPERATURES. THIS WILL HAVE A
SLIGHT EFFECT ON WHAT THE ACTUAL IDLE RPM WILL BE ONCE THE AIRPLANE HAS
BEEN FLOWN FOR A FEW MINUTES (FULLY WARMED UP). THE DIFFERENCE TENDS TO
BE A 50 – 75 RPM INCREASE. FOR THIS REASON, UNLESS YOU ARE DOING THE
CARBURETOR SYNCHRONIZATION PROCEDURE IMMEDIATELY AFTER FLYING THE
AIRPLANE, ADJUSTING FOR AN IDLE SPEED NEAR THE BOTTOM OF THE RECOMMENDED
RANGE WILL NET YOU A PROPER IDLE OF ABOUT 1650 RPM AFTER THE ENGINE IS
FULLY WARMED.
● NOTE: VERIFY THE IDLE SPEED AND ADJUST AS NECESSARY TO ACHIEVE 1600-
1650 RPM AND SMOOTH ENGINE OPERATION (REMEMBER TO ONLY PULL LIGHTLY
AGAINST THE CARBURETORS IDLE STOPS).

VERIFY FUNCTIONALITY OF THROTTLE RETURN SPRING(S)

Special Tools None
Expendable None
Replaceable None
Service Rating Line
Minimum Certification Owner and SPC
1. This section must be done with the aircraft outside.

2. Chock main wheels, tie-down tail.
3. BRAKES: Apply FULL.
4. Start engine, check for oil pressure functioning and showing pressure.
5. Warm the engine to 122°F.
6. THROTTLE- Completely loosen throttle friction knob and observe throttle
advance rate.
If the throttle advances rapidly to a partial position, then slowly

advances the throttle to full, the spring(s) are functioning correctly. This
may take up to 15 seconds. If the throttle is not pulled to full either the
throttle cable needs lubrication or the throttle return spring(s) or throttle
cable need to be replaced.
THROTTLE CABLE LUBE & REPLACEMENT

Special Tools None
Expendable Lightweight Lubricant (LPS2)
Replaceable CT-01200 (iS) or CT-01202 (ULS)
Service Rating Line
If the throttle is not pulled to full during verification (see Verify Functionality of
Throttle Return Springs section) remove and lubricate the cable.
REMOVAL
1. Remove F-01244-L Fwd Tunnel Cover and F-01245-L Aft Tunnel Cover
and loosen the nut clamping the cable to the throttle lever. Remove the
large lock nut from the cable housing attach bracket. Slide the cable thru
the bracket. Remove the second large nut from the cable.
2. Disconnect the cable fwd of the firewall and slide it out the fwd side. See
KAI Sections 49U or 49iS.

INSTALLATION
1. Lubricate the throttle cable internally by holding it vertically, applying lubricant to
the cable and allowing it to run down inside the cable housing while operating it.
Installation procedure is reverse of the removal procedure.
2. If the problem persists after the cable has been lubed replace the throttle
springs. See the Throttle Return Spring Replacement section. If the
problem persists replace the throttle cable.
THROTTLE RETURN SPRING REPLACEMENT

Special Tools None
Expendable None
Replaceable SPRING-00002-L/R-1 (ULS)
Service Rating Line
REMOVAL
1. Remove SPRING-00002-L/R-1 as shown in KAI Section 49U.
INSTALLATION
2. Perform the carburetor sync procedure found in this section.
Reference: Service Bulletin 18-03-06
COWL HINGE PIN LUBRICATION

Expendable Dry lubricant
Replaceable None
Service Rating Line
1. With the cowl hinge pins removed wipe each hinge pin clean.
2. Polish the pins with a fine Scotchbrite® type pad if fretted.
3. Apply lubricant along the length of each hinge pin.

OIL HOSE REPLACEMENT

▲ WARNING: BEFORE PERFORMING ANY INSPECTION OR SERVICE
ALLOW THE ENGINE COMPONENTS TO COOL.
Expendable Plastic tie-wrap 8in

Replaceable Oil Supply Hose, Oil Cooler Hose, Oil Return Hose,
Oil Tank Vent Tube, Oil Vent Interconnect
Service Rating Line
REMOVAL
1. Remove Cowl (12-4).
2. Drain oil system per Rotax Line Maint. Manual including draining of the oil cooler.
3. Cut tie-wraps and detach cushioned clamps from oil hoses.
4. Disconnect and remove oil hoses from the oil tank cover assembly, engine and
oil cooler.
INSTALLATION
1. Installation of new hoses and tubes is reverse of removal procedure.
2. Perform oil purge procedure detailed in Rotax Service Instruction SI-912-018.
COOLING HOSE REPLACEMENT

▲ WARNING: BEFORE PERFORMING ANY INSPECTION OR SERVICE
ALLOW THE ENGINE COMPONENTS TO COOL.
Replaceable FF-1208A, FF-1208B, FF-1220
Service Rating Line
REMOVAL
1. With a catch pan located below the initial hose connection being removed,
remove the spring clamp and disengage the hose from the hose nipple.
2. Disconnect hoses from engine water pump, radiator, and L & R coolant tubes.
3. Cut new hoses to same length as old ones.
4. Remove spring clamps from old hoses and install on new hoses.
INSTALLATION
1. Installation procedure is reverse of removal procedure.
2. Refer to Rotax Line Maint. Manual to refill coolant.

MANIFOLD PRESSURE HOSE REPLACEMENT (ULS)

Tools Wire cutters, straight slot screwdriver(for prying hose)
Expendable Tie wrap
Replaceable Manifold pressure hose
Service Rating Line
Minimum Certification LSA-RM with Rotax Service certification or A&P with
Rotax Service certification
REMOVAL
1. Cut the tie wrap attaching the manifold pressure hose to the manifold pressure
sensor wires.
2. Remove the hose from the manifold pressure sensor and the from the
compensating tube assembly.
INSTALLATION
1. Cut the new hose to the length specified in the KAI.
2. Installation is reverse of removal.
ENGINE REPLACEMENT
Tools Torque wrench, many common tools as req'd.
Expendable Loctite 221, coolant, engine oil
Replaceable Engine
Service Rating Line
Minimum Certification LSA-RM with Rotax Service certification or A&P
with Rotax Service certification
Additional References KAI, Rotax Line and Heavy Maintenance
Manual
REMOVAL
1. Remove battery ground cable from negative battery terminal.
2. Disconnect Heat valve SCAT hoses from heat muff.
3. (ULS only) Disconnect fuel pump drain tube and hose where attached to the
engine.
4. (ULS only) Disconnect oil pressure, EGT, and CHT wires from cylinder heads.
Remove tie-wraps securing wire runs to various engine components as required.
5. Move fuel selector valve to "UP-OFF" position.
6. (ULS only) Place suitable container under gascolator. Remove gascolator
bottom plug and drain fuel from system. NOTE: This is a relatively slow process.

■ WARNING: EXPECT SOME FUEL DRAINAGE TO OCCUR AS THE HOSE CONNECTIONS ARE
REMOVED. USE PROTECTIVE GLOVES AND HAVE SHOP RAGS CLOSE BY.
7. Disconnect fuel hoses at firewall. Some fuel may still be in hoses.
8. Place drain pan beneath engine and drain oil by disconnecting oil hose at pump.
Elevate hose to prevent siphoning oil from tank.
9. Burp engine.
10. Disconnect oil return hose from bottom of engine case.
11. Disconnect oil return hose (where tank is marked "IN") from top of oil tank.
12. Drain cooling system per Rotax Line Maint. Manual.
13. Disconnect throttle and choke (ULS only) cable(s) from carburetor or throttle
body per KAI.
14. If the propeller is to be removed from the engine, measure propeller blade pitch
for reference at reinstallation.
15. (iS Only) Remove right side EFIS screen from instrument panel. If not equipped,
remove fwd. upper skin from fuselage.
16. (iS Only) Disconnect both ECU harness cables from the ECU module (refer to
Rotax documentation)
17. (iS Only) Remove harness cable cover plate from firewall and reposition both
cables to fwd. of the firewall.
18. Disconnect the pitot line from the aft end of the pitot tube.
Refer to KAI for remainder for details on detaching the engine from front of the
fuselage.
INSTALLATION
1. Installation is reverse of removal. Torque fasteners as specified.
2. Refill coolant system to recommended level.
3. Refill oil to recommended level.
4. Purge oil system, etc. refer to the Rotax Line Maintenance Manual for this and
other procedures during and after installation. Also refer to applicable KAI sections
throughout the installation.

Chapter 13 - FUEL SYSTEM
ULS SYSTEM
iS SYSTEM

OVERVIEW ................................................................................................................ 13-2

Components......................................................................................................... 13-3
Fuel System Schematic....................................................................................... 13-4
SERVICE ................................................................................................................... 13-6
Supplies ............................................................................................................... 13-6
Special Tools ................................................................................................................................................13-6
Expendable...................................................................................................................................................13-6
Replaceable..................................................................................................................................................13-6
General ................................................................................................................ 13-6
Draining the fuel system ...............................................................................................................................13-7
Fuel tank removal .........................................................................................................................................13-8
Installation .................................................................................................................................................13-8
Fuel system component removal..................................................................................................................13-8
Installation .................................................................................................................................................13-9
Gascolator cleaning......................................................................................................................................13-9
Installation ...............................................................................................................................................13-10
Coarse fuel tank screen removal ................................................................................................................13-10
Installation...............................................................................................................................................13-10
Fuel pressure/return assembly replacement...............................................................................................13-10
Installation ...............................................................................................................................................13-11
Fuel pressure hose fllush............................................................................................................................13-11
Fuel return hose flow check........................................................................................................................13-12
Fuel drain hose replacement ......................................................................................................................13-13
Removal ..................................................................................................................................................13-13
Installation ...............................................................................................................................................13-13
Fuel prefilter cleaning/inspection ................................................................................................................13-13
Main filter replacement ...............................................................................................................................13-14
Long Term Storage.....................................................................................................................................13-15
Draining The Carburetor Bowl ....................................................................................................................13-15
OVERVIEW
The portion of the fuel system common to both engine models consists of a filler
neck and cap assembly, 20.2 gallon fuel tank, tank fuel level sending unit, mechanical
fuel level gauge, a finger screen fuel strainer at the bottom tank outlet preventing larger
foreign objects from progressing through the fuel system, and a fuel return line.
ULS Engine
The finger screen fuel strainer outlet feeds (in order as listed) a single ES 40135 12V
DC solid-state electric fuel pump located under the mid baggage floor cover. This
serves as an auxiliary fuel pump to the mechanical engine driven pump. The aux. pump
operates full time. The fuel pump outlet feeds (in order as listed) a remote controlled
fuel shut-off valve, gascolator/filter, main fuel line routed fwd. to the firewall, engine
driven fuel pump, and then a fuel distribution manifold feeding both carburetors, the fuel
pressure sensor, and hose that connects to the fuel return line.
iS Engine
The finger screen fuel strainer outlet feeds (in order as listed) a remote controlled fuel
shut-off valve, a fuel system adapter that proves a system sumping low point, pre-filter,
dual pump high pressure fuel pump assembly, manifold block for fuel pump output
pressure transducer, main fuel filter with a check valve and by-pass line (safety bypass

in case of restricted fuel filter), a metered bypass/loop-back manifold assy. located

below the throttle control, main line routing to the firewall, hose routing from firewall to
inlet port on fuel rail (engine right rear), hose connecting outlet of fuel pressure regulator
(engine left rear) to firewall fitting and line feeding back to low pressure side of the
bypass manifold assy., and then back to the fuel tank.
repair processes.
COMPONENTS
1 Fuel cap T-00007A
1 Filler neck assembly T-01231
1 Fuel tank See KAI
1 Fuel strainer/coarse finger screen (ULS) VA-261
1 Fuel strainer/coarse finger screen (iS) VA-265
1 Fuel shut-off valve .250 Pipe Fuel Valve 4161089
1 Fuel Valve Cable Assy., 100” CT-01204
1 Fuel quick-drain CAV-110
1 Fuel sending unit IE F-385B
1 ADAPTOR, .25X.25X.25X.125 NPT FLF-00013
1 Mechanical Fuel Gauge IE-00001
ULS Engine only Shaded parts below
1 Electric fuel pump ES 40135
1 Gascolator GAS-6
1 Left carburetor See Rotax Documentation
1 Right carburetor See Rotax Documentation
1 Mechanical fuel pump See Rotax Documentation
1 Fuel Pressure/Return hose assy. VA-216
1 Fuel pressure sender See KAI
iS Engine only Shaded parts below
Fuel Drain Assy. See KAI
Pre-filter Fuel-FX375-M
Rotax Fuel Pump Assy. See Rotax Documentation
By-pass Check Valve Fuel-CK375-NM-14-BRP
Fuel Filter 874 060 Fuel Filter
Bypass Fitting Assy. See KAI



SERVICE
AVAILABLE.
■ CAUTION: REPLACEMENT FUEL SYSTEM COMPONENTS MUST BE EQUIVALENT TO THE

ORIGINAL PARTS.
● NOTE: CLOSE THE FUEL VALVE TO SERVICE OR REMOVE COMPONENTS THAT ARE
FORWARD OF THE FUEL VALVE. DRAIN THE FUEL SYSTEM TO SERVICE OR REMOVE
COMPONENTS AFT OF THE FUEL VALVE.
SUPPLIES
i Safety wire pliers i Safety wire
i Fuel Container i Pipe Thread Sealant
i 1/8”NPT x 3/8” hose barb
i 3/8” ID fuel hose REPLACEABLE
i Protective Gloves
i Shop Towels i Gas-5 Screen (ULS)
i Torque Wrench i Gas-5 O-ring gasket (ULS)
i Fuel Filter (iS)
GENERAL
AVAILABLE.

DRAINING THE FUEL SYSTEM

Special Tools 1/8”NPT x 3/8” hose barb
12” x 3/8” I.D. fuel hose
Fuel Container
Protective Gloves
Expendable Pipe Thread Sealant
Replaceable None
Service Rating Line
x NOTE: IF THERE IS A FAIR AMOUNT OF FUEL IN THE TANK, REDUCE THE DRAIN TIME BY
FIRST SIPHONING OUT AS MUCH AS POSSIBLE. A SMALL WEIGHT SECURELY ATTACHED TO
THE END OF A FLEXIBLE SIPHON HOSE WORKS WELL FOR REACHING THE TANK 'S
BOTTOM.
1. Move the fuel selector control to the ‘OFF’ position.

2. Remove the access cover plate located below the gascolator (ULS) or fuel drain
assy. (iS).
3. Place a container beneath the gascolator (ULS) or fuel drain assy. (iS) with
sufficient capacity for the fuel in the fuel tank.
■ WARNING: EXPECT SOME FUEL DRAINAGE TO OCCUR AS THE DRAIN VALVE IS REMOVED.
USE PROTECTIVE GLOVES AND HAVE SHOP RAGS CLOSE BY.
4. Remove the CAV-110 drain valve from the bottom of the gascolator (ULS) or fuel
drain assembly (iS).
5. Install the hose barb (with hose attached) in the opening where the fuel drain was
removed.
6. Move the fuel selector control to the ‘ON’ position.
7. Remove the fuel cap from the fuel neck.
■ CAUTION: TURN OFF THE ELECTRIC FUEL PUMP IMMEDIATELY WHEN A CHANGE IN
SOUND IS HEARD, (THE LOUDER / HIGHER FREQUENCY SOUND INDICATES THE FUEL PUMP
IS NO LONGER PUMPING FUEL) DO NOT ALLOW THE FUEL PUMP TO OPERATE
WITHOUT FUEL OR PERMANENT DAMAGE MAY OCCUR.
8. ULS Only - Turn on the master switch and operate the ES 40135 Electric Fuel
Pump until the fuel pump stops pumping fuel.
9. iS Only – Allow the fuel to drain via gravity.
10. Once fuel is fully drained, move the fuel selector control to the ‘OFF’ position.
11. Reinstall the fuel filler cap in the fuel neck.
12. To aid in clearing the fuel lines use low pressure (5-10 PSI max) air applied to

the open end of the fuel drain hose that is connected to the bottom of the
gascolator or fuel drain assy. This will evacuate the majority of the fuel held
within the system, and help prevent fuel loss if system components are being
removed.
13. Repeat Steps 6-9 to remove any remaining fuel from the tank.
14. Remove the fuel drain hose and hose barb, and reinstall the drain valve in the
bottom of the gascolator (ULS) or fuel drain assy. (iS) using pipe thread sealant.
FUEL TANK REMOVAL

Expendable None
Replaceable None
Service Rating Line
1. Drain the fuel system. (13-17)

2. Loosen the two clamps and remove the fuel filler hose from the fuel tank and filler
neck assy.
3. Remove the screws (4) and the center access cover plate on the bottom of the
fuselage.
4. Disconnect the fuel sending unit wire screw (1) from the fuel sending unit.
5. Disconnect the two fuel lines from the bottom of the tank.
6. Remove the bolt (1), washers (2), and nut (1) from each upper outboard fuel tank
attach bracket.
7. Remove the screw and washer from the lower aft fuel tank attach bracket.
8. Remove the fuel tank.
INSTALLATION
FUEL SYSTEM COMPONENT REMOVAL

▲WARNING: BEFORE PERFORMING ANY MAINTENANCE OR REPAIRS TURN THE
MASTER SWITCH 'OFF' AND DISCONNECT THE NEGATIVE (-) BATTERY CABLE FROM
THE BATTERY.

Expendable None
Replaceable None
Service Rating Line
1. Isolate the component from fuel flow with either the fuel shutoff valve or by
draining the fuel tank/system (13-17).
2. Label, and then disconnect the electrical connections attached to the component,
if applicable.
3. Disconnect the fuel line(s) attached to the component, if applicable.
4. Remove the attaching hardware and component.
INSTALLATION

▲WARNING: ALWAYS HAVE AN APPROPRIATE FIRE EXTINGUISHER READILY AVAILABLE.
GASCOLATOR CLEANING/INSPECTION (ULS)

Tools Safety wire pliers
Fuel catch container
Protective Gloves
Expendable Safety wire
Replaceable Gas-5 Screen
Gas-5 O-ring gasket
Service Rating Line
1. Remove the access cover plate located below the Gascolator
2. Move the fuel valve to the OFF position.
■ WARNING: EXPECT SOME FUEL DRAINAGE TO OCCUR AS THE GASCOLATOR BOWL IS
3. Remove the fuel quick-drain to drain the existing fuel from the gascolator bowl.
5. Remove the safety wire and screws (4) from around the gascolator bowl.
Remove the collar and the gascolator bowl. (Note: Have a container available
to catch any spillage of fuel that still remains in the gascolator and fuel
lines).
6. Use a small pointed tool to lift the edge of the filter screen and remove it from the
gascolator housing for cleaning.

INSTALLATION:
1. Installation procedure is reverse of the removal procedure. Use thread sealant
on the threads when re-installing the quick-drain valve.
COARSE FUEL TANK SCREEN REMOVAL

Expendable pipe thread sealant
Replaceable None
Service Rating Line
1. Drain the Fuel System. (13-17)
2. Remove the screws (4) and center access cover plate from the fuselage bottom
skin. (3-4)
3. Disconnect the fuel line (aft most fitting) from the fuel strainer on the bottom of
the tank.
4. Unthread the fuel strainer from the fuel tank.
5. Clean the screen and inspect same for breakage or separation from fitting.
Installation:
1. Installation procedure is reverse of the removal procedure. Apply thread sealant
paste to fuel strainer pipe threads before installation.
FUEL PRESSURE/RETURN ASSEMBLY REPLACEMENT (ULS)

Special Tools torque wrench(in-lb)
Protective Gloves
Replaceable VA-216 Fuel Pressure/Return Assembly
Service Rating Line
Minimum Certification LSA-RM with Rotax Service certification of A&P
with Rotax Service Certification
NOTE: WHEN LOOSENING OR TIGHTENING THE BANJO BOLT SUPPORT THE CLAMP BLOCK
(FUEL MANIFOLD) APPROPRIATELY.
■ WARNING: EXPECT SOME FUEL DRAINAGE TO OCCUR AS THE HOSE CONNECTIONS ARE
1. Drain fuel system forward of fuel valve. (13-4)

2. Disconnect both ends of Fuel Pressure/Return Assembly.
3. Remove banjo bolt M8X1X17 from top of clamp block.
4. Cut tie-wraps and remove Fuel Return Assembly.

Installation:
1. Installation of new hose assembly is reverse of removal procedure. Rotax
specifies that new copper crush washers be used.
2. Torque banjo bolt M8X1X17 to 90 in-lbs.
Figure 31: Fuel Pressure Hose Flush
FUEL PRESSURE HOSE FLUSH (ULS) ( LEFT SIDE OF VA-216 HOSE ASSEMBLY)
Expendable NA
Replaceable NA
Service Rating Line
1. Place towels beneath the Fuel Pressure Sender.
■ WARNING: EXPECT SOME FUEL DRAINAGE TO OCCUR AS THE HOSE CONNECTION IS


2. Loosen VA-216 Fuel Return Assembly hose coupling while supporting elbow with
second wrench.
3. Place container beneath hose and remove hose from fitting.
4. With end of hose inside container, flush hose by turning on fuel boost pump for
two seconds.
5. Reinstall hose to elbow.
FUEL RETURN HOSE FLOW CHECK (ULS) ( RIGHT SIDE OF VA-216 HOSE ASSEMBLY)
Special Tools Protective Gloves

Expendable NA
Replaceable NA
Service Rating Line
1. Place towels beside the Fuel Return hose connection at the firewall.
■ WARNING: EXPECT SOME FUEL DRAINAGE TO OCCUR AS THE FUEL HOSE IS REMOVED.
2. Remove the VA-216 Fuel Return Assembly hose coupling from the firewall fitting
and quickly move it to a higher position to prevent fuel from leaking.
3. Place the hose end in a graduated container and operate the electric fuel pump
for one minute. Confirm that the captured fuel measures at least 3 oz. If it does
not, remove the hose assembly (13-20) and clear any blockages at the restrictor
orifice located within the dual barbed banjo fitting, and then reinstall the hose
assembly, and retest.
4. Reinstall the hose to the firewall fitting.

FUEL DRAIN HOSE REPLACEMENT (ULS)

Expendable Tie wraps (2)
Replaceable Fuel interconnect and drain hoses
Service Rating Line
Removal
1. Cut the tie wraps attaching the drain hose to the gascolator-to-fuel-pump
hose.
2. Loosen two hose clamps on the interconnect hose and one clamp on the
drain hose and slide the clamps onto the aluminum drain tube.
3. Remove the hoses.
Installation
1. Install new hoses onto the fuel pump drain fitting and the drain tube.
2. Slide hose clamps back into position over the hoses and tighten.
3. Secure the drain hose to the gascolator-to-fuel-pump hose using tie wraps.
FUEL PRE-FILTER CLEANING/INSPECTION (iS)

Safety Wire
Expendable NA
Replaceable NA
Service Rating Line
2. With a container positioned below to catch draining fuel, remove the quick drain
fitting from the fuel drain assembly
3. Slightly loosen the fitting at the upper end of the prefilter to fuel pump line and
wait for fuel to stop draining from the fuel drain assembly.
4. Place towels beneath the fuel prefilter.
■ WARNING: EXPECT SOME FUEL DRAINAGE TO OCCUR AS THE LINE CONNECTIONS ARE
5. Remove the lines from both ends of the prefilter

6. Loosen the clamp retaining the filter to the mounting bracket, and remove the
filter.

7. Remove safety wire from end of filter and thread the end of the filter out of the
filter body.
8. Inspect / clean the filter and interior of filter body.
9. Reassemble the filter and install safety wire.
10. Reinstall Pre-filter in reverse order of removal.
11. Double check that all lines are properly tightened and then move the fuel selector
control to the ‘ON’ position and check for leaks at all fittings.
MAIN FUEL FILTER REPLACEMENT (iS)

x NOTE: The fuel filter should be replaced in the time interval prescribed in the
Service Schedule Checklist or any time the fuel pressure is operating above the
normal operating range.

Pipe thread sealant
Expendable NA
Replaceable NA
Service Rating Line
2. Place towels beneath the Main Fuel Filter.
■ WARNING: EXPECT SOME FUEL DRAINAGE TO OCCUR AS THE LINE CONNECTIONS ARE
■ CAUTION: TURN OFF THE ELECTRIC FUEL PUMP IMMEDIATELY WHEN A CHANGE IN
SOUND IS HEARD, (THE LOUDER / HIGHER FREQUENCY SOUND INDICATES THE FUEL PUMP
IS NO LONGER PUMPING FUEL) DO NOT ALLOW THE FUEL PUMP TO OPERATE
WITHOUT FUEL OR PERMANENT DAMAGE MAY OCCUR.
3. With a helper inserting a fuel sample tube into the fuel drain, run each fuel pump
momentarily to clear some of the fuel from the pump manifold.
Do not continue running the pumps after the sound pitch changes. (Indicating
they have run dry)
4. Disconnect the F-12127D Fuel Line from the outboard banjo fitting located at the
outlet side of the Fuel Filter, and if available seal the fitting with a cap to prevent
fuel spillage.

5. Disconnect the upper end of the F-12127G Fuel Line from the Fuel Pump
Manifold, and if available seal the fitting with a cap to prevent fuel spillage.
6. Disconnect the wiring harness from both fuel pumps and the fuel pressure
sensor.
7. Remove the 6 screws attaching the Fuel Pump / Filter Assembly to the bulkhead
and remove the assembly from the aircraft.
8. Place the assembly in a shallow catch pan to contain any fuel spillage.
9. Remove the FLF-00020 banjo bolt at the inboard end of the fuel filter.
10. Fully remove the banjo bolt (1) and FLF-00024 seal washers (3).
11. Loosen the clamp retaining the main filter to the mounting bracket and unthread
the main filter from the FLF-00013 manifold/fittings assemble by threading it off of
the FLF-00021 nipple fitting.
12. At reinstallation the FLF-00022 and FLF-00024 washers may be reused if the
rubber seal is undamaged. Reinstall the main fuel filter assembly and related
lines in the reverse order as removed. Pay particular attention to proper
positioning/centering of the seal washers on the fittings.
13. Double check that all lines are properly tightened and then move the fuel selector
control to the ‘ON’ position, activate fuel pump 1 and check for leaks at all fittings.
LONG TERM STORAGE

1. Follow ROTAX engine preservation and storage. See ROTAX Operator’s
manual.
2. Drain the fuel system unless filled with 100LL. See “Draining The Fuel System”
3. If 100LL is not used, drain the carburetor bowls (if installed). See Draining the
Carburetor Bowls.
DRAINING THE CARBURETOR BOWLS

Expendable NA
Replaceable Fuel bowl gasket
Service Rating Line
1. Loosen the hose clamp on the rubber boot attaching the carburetor to the intake
manifold.
2. Disconnect the spring and pull the carburetor aft out of the boot.

■ WARNING: EXPECT SOME FUEL DRAINAGE TO OCCUR AS THE BOWLS ARE REMOVED.
3. Slide the wire bail aft, remove the bowl, and drain the fuel.
4. Inspect gasket for integrity and position prior to installation.
5. Bowl installation is reverse of removal.

Chapter 14 - EXHAUST SYSTEM
OVERVIEW ................................................................................................................ 14-2

Components......................................................................................................... 14-2
SERVICE ................................................................................................................... 14-2
Supplies ............................................................................................................... 14-2
Special Tools ................................................................................................................................................14-2
Expendable...................................................................................................................................................14-2
Replaceable..................................................................................................................................................14-2
General ................................................................................................................ 14-3
Exhaust system removal...............................................................................................................................14-3
Installation .................................................................................................................................................14-3
Ball joint lubrication.......................................................................................................................................14-4

OVERVIEW
The primary purpose of the exhaust system is to direct engine combustion
gasses and heat away from the aircraft, components and occupants. The purpose of the
muffler is to reduce engine noise and allow attachment of a heat muff for heating cabin
air.
x NOTE: THIS MAINTENANCE MANUAL IS INTENDED TO BE USED IN CONJUNCTION WITH THE

RV-12IS KIT ASSEMBLY INSTRUCTIONS (KAI) WHEN COMPLETING MAINTENANCE OR REPAIR
PROCESSES.
COMPONENTS
1 each Cylinder #(x) Exhaust (1) EX-00026-1
(ULS) (2) EX-00027-2
(3) EX-00028
(4) EX-00029
1 each Cylinder #(x) Exhaust (1) EX-00021-1
(iS) (2) EX-00022-2
(3) EX-00023
(4) EX-00024
1 Muffler Assembly EX-00030
8 Joint spring 938 795
8 Exhaust M8-WS12 Lock Nut 842 950
2 Exhaust Flat Spring EX-00045
4 Hose Clamp HW-00017
SUPPLIES
SPECIAL TOOLS i LOCKING PLIERS
EXPENDABLE REPLACEABLE
i Anti-seize compound, high temp i See component list above except
i Exhaust M8-WS12 Lock Nuts M8 Nuts.
i RTV, high temp
i Safety wire

GENERAL
EXHAUST SYSTEM REMOVAL/INSTALLATION

▲ WARNING: ALLOW THE EXHAUST COMPONENTS TO COOL BEFORE PERFORMING
INSPECTION OR SERVICE.
Expendable Anti-seize compound, High Temp.

RTV, High Temp.
Safety Wire
Replaceable Joint spring
M8-12WS Nuts
Service Rating Line
1. Remove the engine cowling. (12-4)

2. Remove the EGT sensor probe from any pipe equipped – ULS (2), iS (4)
3. Remove the two upper SCAT hoses from the heat muff outlets.
x NOTE: TO AVOID NICKING THE EXHAUST ATTACH SPRINGS, CLAMP A SHORT

LOOP OF SAFETY WIRE IN LOCKING PLIERS. HOOK THE LOOP ONTO THE SPRING
AND THEN PULL TO REMOVE THE SPRING.
4. Remove the muffler attachment springs (8) and muffler.

5. Remove the two nuts and the exhaust tube from each cylinder exhaust port.
INSTALLATION
1. Lubricate the ball and slip joints. (14-4)
3. Verify that each spring has an RTV stripe on each side and apply an RTV blob to
each spring end.

BALL & SLIP JOINT LUBRICATION

▲ WARNING: ALLOW THE EXHAUST COMPONENTS TO COOL BEFORE PERFORMING
INSPECTION OR SERVICE.
Required tools Locking pliers

Required expendables Anti-seize compound
Replaceable None
Service rating Line
Additional Reference KAI
1. Remove the two SCAT hoses from the upper outlets on the heat muff.
x NOTE: TO AVOID NICKING THE EXHAUST ATTACH SPRINGS, CLAMP A SHORT

LOOP OF SAFETY WIRE IN LOCKING PLIERS. HOOK THE LOOP ONTO THE SPRING
AND THEN PULL TO REMOVE THE SPRING.
2. Remove the muffler attachment springs (8) and muffler.

3. Apply a generous amount of anti-seize compound to the exhaust tube where it
meets the muffler socket.
4. Apply a light coating of anti-seize compound to the Cylinder #1 Exhaust slip
joints.
5. Reinstall the muffler in reverse order of removal.
6. Verify that each spring has an RTV stripe on each side and apply an RTV blob to
each spring end.
EXHAUST FLAT SPRING REPLACEMENT

Required tools Flat-head Screwdriver
Required expendables None
Replaceable Exhaust flat springs
Hose clamps
Service rating Line
Additional Reference KAI

1. Remove the hose clamps and exhaust flat springs from the Cylinder #1 Exhaust
slip joints.
2. Install new exhaust flat springs and hose clamps to the Cylinder #1 Exhaust slip
joints.
3. Verify that the upper exhaust flat spring and hose clamps do not interfere with the
cowling after installation.

Chapter 15 - PAINTING AND COATINGS
OVERVIEW ................................................................................................................ 15-2

SERVICE ................................................................................................................... 15-3
Supplies ............................................................................................................... 15-3
Tools.............................................................................................................................................................15-3
Expendable...................................................................................................................................................15-3
Replaceable..................................................................................................................................................15-3
Powder coat repair .......................................................................................................................................15-3
Primer repair.................................................................................................................................................15-4
Decorative paint repair .................................................................................................................................15-5

OVERVIEW
● NOTE: REFER TO KAI – SECTION 4 AND 5 FOR ADDITIONAL INFORMATION.
The aluminum skins used on the RV-12iS aircraft are all 2024-T3 alloy. They are
"Alclad", meaning both sides of the sheet are coated with pure aluminum during
manufacture. The thickness of the Alclad layer on aluminum sheet 1/16 inch thick or
less is 5% of the sheet thickness. Alclad on aluminum sheet greater than 1/16 inch thick
is 2.5% of the sheet thickness.
All non-Alclad aluminum parts such as 6061-T6 must be primed for corrosion
protection. Aluminum tubing (other than fluid lines) must be primed on both the interior
and exterior surfaces.
Aluminum bar, angle and tube used in the RV-12iS are not Alclad and must be
primed to ensure corrosion resistance. Zinc Chromate has been the traditional primer
used on aircraft aluminum. With proper surface cleaning this is still a good choice.
There are however many superior primers now available. Most of these are two part,
catalytic curing primers. Generally speaking it's preferable to replace a coated part with
a coated part.
Following is a partial list of suitable primers:
i DUPONT VERI-PRIME (PRIMER #615 and CONVERTER #616S)
i DITZLER DP-40/50 EPOXY PRIMER
i TEMPO brand Chromate in a spray can
i PRATT & LAMBERT Vinyl Zinc Chromate, EX-ER-7 and T-ER-4 Reducer
i SHERWIN WILLIAMS WASH PRIMER #P60G2 and Catalyst Reducer #R7K44
i MARHYDE self-etching primer, available in a spray can as well as quarts
Decorative paint on the structure of the aircraft can be touched-up by the sport
pilot certified owner or a certified repairman with ‘maintenance’ rating. Control surfaces
can only be repainted by an LSA repairman with a ‘maintenance’ rating or an A&P.
Part replacement must be consistent with the original KAI from Van’s Aircraft.
Priming factory Alclad replacement parts remains at the repairman’s discretion. Non-
Alclad parts must be primed per the KAI. Any parts that require replacement due to
corrosion warrant additional corrosion protection on the replacement part. When in
doubt, prime the part.

SERVICE
▲ WARNING: PAINT OR SOLVENT MUST USED IN ACCORDANCE WITH THE
MANUFACTURERS INSTRUCTIONS.
▲ WARNING: DO NOT USE ANY TYPE OF BODY FILLER ON THE AIRCRAFT.
▲ WARNING: DO NOT DAMAGE ANY RIVET HEADS WHEN PREPARING A SURFACE
FOR TOUCH-UP PAINT.
■ CAUTION: EXPOSED STEEL MUST BE CLEANED AND COATED WITH PRIMER OR
POWDER COAT TOUCH-UP PAINT.
■ CAUTION: ANY SCRATCH THAT MAY HAVE PENETRATED THE ALCLAD COATING
MUST BE CLEANED AND PRIMED PROPERLY.
SUPPLIES
i Scotchbrite® type pad i Touch-up paint
i Sandpaper (various grades) i Primer
i Decorative touch-up paint
REPLACEABLE
i None
POWDER COAT REPAIR

▲ WARNING: IF CRACKS, PENETRATING RUST OR CORROSION ARE FOUND IN THE
COATING SURFACE OF POWDER-COATED, PRIMED OR PAINTED PARTS, THE PART
SHOULD BE CAREFULLY INSPECTED UNDER THE COATING FOR MATERIAL DAMAGE . IF
IN DOUBT THE PART SHOULD BE REPLACED.

Special Tools Sandpaper

Scotchbrite® type pad
Expendable Primer
Touch-up paint
Replaceable None
Service Rating Line
Minimum Certification Total area 4 in² or less - Owner and SPC
Total area greater than 4 in² - LSA-RM or A&P
1. Use coarse grit sandpaper to remove the entire area of loose, stained or cracked
coating. Discolored powder coat could conceal underlying rust damage and
requires removal.
2. Gradually progress to finer grit sandpaper to achieve a smooth, gradual taper to
undamaged coating.
3. Clean and dry the entire prepared area.
4. Apply primer and touch-up paint to the entire prepared area.
PRIMER REPAIR
● NOTE: WHEN PRIMING A REMOVABLE PART BETTER RESULTS CAN BE ACHIEVED BY
REMOVING THE PART.
Special Tools Scotchbrite® type pad

Sandpaper
Expendable Primer
Replaceable None
Service Rating Line
Minimum Certification Static structure:
Total area 56 in² or less - Owner and SPC
Control surface:
1. Remove any loose or damaged primer.
2. Use progressively finer grit sandpaper to achieve a smooth, gradual taper to
undamaged primer.
4. Apply primer to the entire prepared area.

DECORATIVE PAINT REPAIR

■ CAUTION: ANY SCRATCH THAT HAS PENETRATED TO THE METAL MUST BE
CLEANED AND PRIMED PRIOR TO APPLYING DECORATIVE PAINT.
● NOTE: WHEN PRIMING A REMOVABLE PART BETTER RESULTS CAN BE ACHIEVED BY
REMOVING THE PART.
Special Tools Scotchbrite® type pad

Sandpaper
Expendable Applicable touch-up paint
Primer
Replaceable None
Service Rating Line
Minimum Certification Static structure:
Total area greater than 64 in² - LSA-RM, or A&P
Control surface:
Total area greater than 16 in² - LSA-RM, or A&P
1. Remove any loose or damaged paint.
2. Use progressively finer grit sandpaper to achieve a smooth, gradual taper to
undamaged paint.
4. Apply primer and touch-up paint to the entire prepared area.


Chapter 16 - TROUBLESHOOTING
Symptom Possible Causes Related
Chapter
Recurring blown fuse i Short in circuit
8
i Overloaded circuit
Engine will turn over, i Insufficient ignition source 8
fails to start
i Insufficient fuel supply to engine 13
i Insufficient air supply to engine 12
Engine fails to turn i Insufficient battery power
over
i Blown ‘Start’ fuse
8
i Master or starter relay malfunction
i Starter malfunction
Heater air is cool i Engine below operating temperature.
i Blockage in coolant system 12
i Air leak around heater box
Vent door stuck i Damage to fuselage 3
i Damage to vent 5
i Over tightened vent hardware KAI
Wing attach pin very i Insufficient lubrication 5
difficult to insert or
i Structural damage 3
remove
i Wing not fully inserted 5
i Force applied to wing
Pulls to one side during i Low tire pressure 1
taxiing (level surface)
i Dragging brake 7
i Damage to landing gear KAI
i Axle nut over tightened KAI
Difficult to turn while i Brake malfunctioning 7
taxiing
i Nose fork over tightened KAI
Shudder after touch- i Nose fork under tightened 5
down
i Out of balance wheel assembly 5

Symptom Possible Causes Related

Chapter
Low frequency Out of balance nose wheel assembly 5
vibration in flight
Vibration at idle i Propeller installed incorrectly 11
i Propeller unbalanced 11
i Idle RPM too low Rotax line maint.
i Carb. sync. out of balance (ULS) Rotax line maint.
i Engine suspension loose 3
Vibration at specific i Carburetor malfunction 12
RPM
i Ignition malfunction Rotax line maint.
Excessive rattling i Loose fasteners
3
i Loose baggage
Corrosion i Loose electrical connection 8
i Exposure to contamination 3
i Failing protective coating 15
i Unlike metals exposed to moisture 15
Flight control i Insufficient lubrication 2
resistance
i Control surface hinge axis not aligned 5-17
i Failing control system components 6
i Improper control system adjustments KAI
Erroneous engine i Malfunctioning sensor 8
status
i Loose connection 3
i Malfunctioning EMS 9
Abnormal engine noise i Damaged or leaking exhaust system 14
i Open passage in firewall 3
Excessive fuel i Blocked fuel return hose orifice 13
pressure (ULS)
Excessive fuel i Restricted Fuel filter 13

pressure (iS)

BRP UTILITY AND DIAGNOSTIC SOFTWARE (BUDS)

A maintenance port is located beneath the instrument panel to the right of the center
console to accommodate the BUDS ECU 9 pin d-sub. See Figure.
BUDS is a ROTAX product designed to read and extract data from the 912iS ECU
(Engine Control Unit). The BUDS system utilizes BRP windows-based software, and a
specific USB-to-CAN converter (dongle).
The converter, BUDS Set Level 2, P/N 864 022, is designed for trained and certified
mechanics and allows the user to reset faults.
Owners of the aircraft do not have to purchase a BUDS system to view error codes.
To view ROTAX 912iS fault information via EFIS scan the following QR code:
Or enter the URL: https://www.vansaircraft.com/qr/rotax-diag/


Chapter 17 - FEEDBACK & REPLACEMENT

PARTS
FEEDBACK
To maintain the highest level of safety Van’s Aircraft Inc. requests and the FAA
requires notification of any safety of flight issue, service, or maintenance difficulty that
could compromise airworthiness of the RV-12iS aircraft. A feedback form is provided
in the Supplement section of this manual.
A valuable description will include:
x Specific flight condition if applicable.
x List of the parts identified as affected by the anomaly.
x Description of the apparent condition of the parts prior to the anomaly (de-burred,
primed, modified, etc.)
x Statement as to whether the aircraft has remained within the operating limitations
defined in the POH.
x Brief description of the type and frequency of aircraft use (may include; runway
conditions, flying conditions, storage methods, etc.)
REPORTING METHODS
Mail to:
ATTN: RV-12iS Safety Alert
Van's Aircraft, Inc.
14401 Keil Road, NE
Aurora, OR 97002 USA
Fax to:
'RV-12iS Safety Alert' (on cover page)
503.678.6560
Hours: 24 hours per day
E-mail to:
'RV-12iS Safety Alert' (in subject line)
[email protected]

REPLACEMENT PARTS
Van's Aircraft Inc. reserves the right to update, modify or discontinue any part
without notice. Van's Aircraft Inc. is not liable for the use of any part or material by the
owner that does not appear on the kit's part list. Use of any unauthorized part or
material will be at the owner/operators own risk.
For replacement parts contact Van's Aircraft Inc. using the information found on
page iv.
Part number and description may be obtained from the Kit Assembly Instructions.
Whenever ordering replacement parts please provide the following information:
Name
S-LSA Serial or E-LSA Builder Number
Day Phone
Fax (if applicable)
Email
Ship to Address:
Address
City
State/Province
Zip/Postal Code
Country
Part Number
Description
Quantity
Payment method and corresponding account #, & exp. date (if applicable)

SUBSTITUTE PARTS
The following parts are approved for substitution. Either the original part or substitute
part is acceptable for installation in the aircraft.
Oil System (Note: There was no 'original part' in this case.)

FUMOTO F107N 12mm-1.75 Quick Oil Drain Plug ↔ CCA-2450 Valve and CCA-2474
Extension ↔ SAF-AIR M12175 Valve and RM12175 Extension.
Torx Drive Screw

AN526C832-R8 Phillips Truss SS X 1/2 in ↔ Fastenal 0175181 Torx, Pan Head,
SS X 1/2 in (0175180, 3/8 in) NOTE: May be used in place of screws that hold all
interior panels.
Rivets
AN470AD rivets may be substituted for specified LP4 rivets.
AN426AD4 rivets may be substituted for specified CS4 rivets
Cherry Max CR series rivets may be substituted for any AN470AD rivet or LP4 rivet.
CCR rivets and solid AN426AD3 rivets, used for attaching nutplates, may be used
interchangeably. AN426AD3 rivets are preferred for strength wherever they can be
accommodated.


Chapter 18 - SUPPLEMENT
SERVICE SCHEDULE CHECKLIST..........................................................................................................................................18-3

INSPECTION CHECKLIST......................................................................................................................................................18-7
ELECTRICAL SYSTEM SCHEMATIC………….........................................................................................................................18-29
3 VIEW.............................................................................................................................................................................18-31
FEEDBACK FORM..............................................................................................................................................................18-33


SERVICE SCHEDULE CHECKLIST

Service Next
What Action When How Date Due Initial
Aircraft Inspection Annual or 100 hours 3-1
AOA wing root connection Lubricate and Every wing removal 5-26
Test, as required
AST attach hinge Lubricate Annual or 100 hours 5-27
Battery Charge As needed 8-12
Brake fluid Flush & replace 5 years 7-5
Brake pedal components Lubricate 2 years or 200 hours 7-4
Brake shoe linings Replace As needed 7-6
Cable end hardware Lubricate Annual or 100 hours 6-9
Control system cable tension Check Annual 6-3
Control system rod ends Lubricate Annual or 100 hours 6-8
Coolant Hoses Replace 5 years 12-11
EFIS software Check for updates Annual or As needed Dynon or Garmin
user’s manual
ELT Self Test 3 Months See Mfr’s Manual
ELT Inspection 12 Months See Mfr’s Manual
ELT Remote Control Panel Replace 5 years See Manufacturer’s
Battery - Alkaline Manual
ELT Remote Control Panel Replace 10 years See Manufacturer’s
Battery - Lithium Manual
ELT Audio Alert Indicator Replace 10 years See Manufacturer’s
Battery Manual
Engine coolant Replace 5 years Rotax maintenance
manual
Engine service procedures Check & perform 100 hours Rotax maintenance
manual
Exhaust ball joints Lubricate Annual or 100 hours 14-4
Exhaust flat springs Replace 300 hours 14-4


SERVICE SCHEDULE CHECKLIST(CONTINUED)

Service Next
What Action When How Date Due Initial
Flaperon bearings Lubricate 6 months or as needed 5-27
Flaperon control connection Lubricate Each removal 5-26
Fuel Drain Hose (ULS) Replace 5 years or with fuel 13-10
pump replacement
Fuel Filter (iS) Replace After first 100 hours, 13-12
then each 200 hours or
with any fuel pressure
indications above
normal range
Fuel Pressure Hose (ULS) Flush Annual or 100 hours 13-9
Fuel Return Hose (ULS) Flow check Annual or 100 hours 13-10
Fuel Tank Finger Strainer Clean & inspect One time per year 13-8
Gascolator (ULS) Clean & inspect Annual or 100 hours 13-7
Landing gear attach hardware Torque Annual or 200 hours 3-13
Manifold Pressure Hose Replace 10 years or eng. ovhl. 12-11
Nose fork pivot Lubricate Annual or 100 hours 5-28
Nose wheel bearings Replace As needed 5-27
Oil Supply Hoses Replace On condition 12-10
Propeller Hub Clamping Bolts Torque Annual or 100 hours 11-3
Throttle Return Spring(s) Verify Function 50 hours or after 12-14
carburetor maintenance
Wing Attach Locations Lubricate Each removal 5-23
Wheel Balance Balance As needed 5-29
Wheel bearings (Main) Lubricate 2 years or as needed 5-25
End of service schedule


INSPECTION CHECKLIST
RV-12iS Aircraft Inspection Reg. Number:
Airframe S/N: Engine S/N:
Airframe TT: Engine TT:
Inspection Date: Inspector:
Check all that apply to inspector and inspection:
____ Owner ____ Operator ____ Pilot ____ A&P ____ LSA Repairman Inspection ____ LSA Repairman Maintenance
____ 100 hour ____ Annual ____ Extreme Conditions ____ After Hard Landing
Category: Check:
Documents Pass Fail
Certificate of Airworthiness Onboard and Displayed
Registration Onboard and Accurate
POH Onboard
Operating Limitations Onboard
Switch and control placards Secure / Legible
Identification Plate Secure / Legible / Accurate
“Light Sport” Placard (“Experimental” for E- Displayed
LSA)
Weight & Balance / Equipment List Onboard
Service Schedule Check Items due for service
Systems & Controls Test Operations / Values Pre-Inspection Post-Inspection

Engine Start Procedure Effective / Complete
Starter Operational / Strong
Engine Run-Up Refer to Rotax Line Maintenance Manual
Continued on next page


Pass Fail
Left and Right Wing Secure / Smooth operation of ailerons and
flaps
Brake System Operation
Fuel Level Correct Indication
Verify function of throttle return springs Springs pull throttle to wide open with friction
control off (see procedure page 12-10)
Static RPM at full throttle Operational / RPM ________________
Electrical System Operational / Volts:_________
Amps:_________
Cool Down & Shut Down Effective / Normal
Fluids (Oil, Hydraulic, Fuel, Coolant) Leak / Level Check
Stall warning Tone present in headphones when stall sense
switch is lifted
Lighting Check for proper operation of all exterior lights


Notes:
Cockpit Check
Complete Pre-Inspection procedure Step 1-5 (Page 3-3) Pass Fail
Aft Face of Firewall Cracks / Deformation
Rudder Pedal Assemblies Cracks / Proper operation
Brake Pedal Assemblies Proper Operation / Leaks
Control Sticks Proper Operation
Control system cables Tension / Wear / Fraying
Control system Excess play / Friction / Proper operation
Control Stops Security / Deformation / Proper Adjustment
Seat Belts Security / Damage
Seats Cracks / Security


Roll Bar, and Canopy Frame Security / Cracks / Proper Latch Operation
Control / Instrument Panels Proper Placards Installed
Control / Instrument Panels Security / Connections
Fuses Security / Condition / Spares
Air & Heat Vents Operation / Security
Engine Throttle Control Cable Operation / Kinks / Interference
Fuel selector Control ON/OFF Kinks / Interference / Operation (Confirm full
valve movement between ON and OFF position)
Wiring Harness Condition / Connections / Security
System Lines (Fuel, Brake, Static) Security / Routing / Condition / Fittings
Fuel System Components Security / Leaks
Fuel Strainer / Gascolator [ULS only] Clean/Secure
Fuel Coarse Filter [iS only] Clean/Secure
Fuel Filter [iS only] Replace as prescribed in Service Schedule
Checklist
Avionics Inspect per Manufacturer Manual Pass Fail

Each Main Unit Condition / Security
Wiring & Conduit Chafing / Routing / Security
Connections Corrosion / Security
Antenna Mounts Condition / Security
Optional Equipment Throughout Inspect per Manufacturer Manual Pass Fail


Emergency Locator Transmitter Comply with current FAR 91.207 Pass Fail
"G" Switch Also refer to current CFR 91.207
Calendar date Also refer to current CFR 91.207
Battery Condition Also refer to current CFR 91.207
Audio Alert Indicator Battery See Manufacturer’s Manual
Remote Control Panel Ind. Battery See Manufacturer’s Manual
Self Test See Manufacturer’s Manual
Propeller Refer to Sensenich Manual Pass Fail

Spinner / Back-plate Cracks / Deformation
Blades Delamination / Cracks / Damage
Hardware Condition / Torque
Hub Fasteners / Security
Gear Box Leaks / Fasteners / Security
Prop Track Measure difference in blade track


Engine Refer to Rotax Manual Pass Fail

Engine and components Comply with Rotax manufacturer inspection
recommendations and procedures (Rotax Line
Maintenance Manual)
Firewall Forward Check Pass Fail

Overall insp. of Engine Compartment Leakage / Corrosion / Wear
Fwd. Face of Firewall Deformation / Cracks / Unsealed holes
Engine Mount Cracks / Signs of Fatigue / Corrosion
Vibration Isolators Cracks / Deterioration
Engine Mount & Isolator Hardware Condition / Torque
Wiring Harness Condition / Connections / Continuity
Battery Condition / Corrosion / Security / Charge
Cabin Heat valves and controls Security / Condition / Operation
Throttle Control Cable(s) Operation / Condition / Connection
Choke Control [ULS only] Operation / Condition / Connection
Air Filter(s) Clean / Secure
Heat Exchangers (oil & coolant) Leaks / Condition / Security
Evaluate life limited parts Check for last replacement
System Lines (Fuel, Pitot) Security / Routing / Condition
Fuel, Oil, and Coolant hoses and lines Condition / Security
Heat Muff and Muffler Deformation / Wear / Leakage
Cowling Condition / Fasteners / Attach Hinges


Empennage Check Pass Fail

Vertical Stabilizer Skins Deformation / Cracks / Signs of Wear / Corrosion
Vertical Stabilizer Skin Rivets Missing / Deformed
Vertical Stabilizer Fwd. Spar Deformation / Cracks / Signs of Wear
Vertical Stabilizer Rear Spar Deformation / Cracks / Signs of Wear
Vertical Stabilizer Fiberglass Fairing Condition / Security
Vertical Stabilizer to Rudder Interface Signs of Wear / Contact
Vertical Stabilizer Interior Structure Deformation / Cracks / Signs of Wear / Corrosion
Rudder Skin Deformation / Cracks / Signs of Wear
Rudder Skin Rivets Missing / Deformed
Rudder Spar and Hinge Brackets Deformation / Cracks / Signs of Wear
Rudder Fiberglass Fairing Condition / Security
Rudder Control Horn Coating Damage / Cracks / Deformation / Missing
Fasteners
Rudder Control Cables Swages / Fasteners
Rudder Stops Wear / Deformation
Rudder Confirm Freedom of Movement
Stabilator Skins Deformation / Cracks / Signs of Wear / Corrosion
Stabilator Skin Rivets Missing / Deformed
Stabilator AST Attachment Wear / Security / Safety Wire
Stabilator Box Spar Deformation / Cracks / Signs of Wear / Corrosion
Stabilator Ribs Deformation / Cracks / Signs of Wear / Corrosion
Stabilator Control Horns Coating Damage / Cracks / Deformation
Stabilator C’ Balance Arm & Brackets Deformation / Cracks / Signs of Wear / Corrosion
Stabilator Hinge Brackets Deformation / Cracks / Signs of Wear / Corrosion
Stabilator Proper Movement


Empennage (Continued) Check Pass Fail

Anti-Servo Tab Skins Deformation / Cracks / Signs of Wear / Corrosion
Anti-Servo Tab Skin Rivets Missing / Deformed
Anti-Servo Tab Spar / Hinge Deformation / Cracks / Signs of Wear
Anti-Servo Tab Control Horn Attach. Deformation / Cracks / Signs of Wear
Pitch Trim Push/Pull Rod and Link Damage / Signs of Wear / Play
Pitch Trim Servo and Tray Cracks / Deformation
Pitch Trim Tray Hardware Wear / Play
Pitch Trim Servo Wiring Connections / Condition
Anti-Servo Tab Operation Binding / Interference
Landing Gear Check Pass Fail
Main Gear Legs / Brackets Security / Wear / Corrosion or Bubbled Paint
Landing Gear Attach Hardware Torque
Gear Legs Bubbled Paint / Corrosion / Straightness
Brake Hydraulic Lines Leaks / Security / Wear
Wheel Bearings Lubrication / Free Play (Refer to Matco manual)
Brake Calipers Condition / Play (Refer to Matco manual)
Brake Shoes Lining Limit (Refer to Matco manual)
Brake Disks Cracks / Deformation / Thickness (Refer to Matco
manual)
Wheels Alignment / Cracks (Refer to Matco manual)
Tires & Valve Stem Wear / Cracks / Air Pressure
Nose Gear and Fork Travel / Security / Break-out Force / Internal* Cor.


Fuselage Check Pass Fail

Skins Deformation / Cracks / Signs of Wear / Corrosion
Footprint Area of Left & Right Wing Signs of Wear / Cracks / Damaged Fasteners
Bulkheads & Stringers Deformation / Cracks / Signs of Wear / Corrosion
Left & Right Static Ports Clean / Clear / Secure
Wing Electrical Connectors Corrosion / Damage
Flaperon Torque Tube Corrosion / Cracks / Presence of Spacers
Left & Right Boarding Step Security / Cracks / Seal


Wings / Center Section Check Pass Fail

Skins Deformation / Cracks / Signs of Wear / Corrosion
Ribs & Attach Angles Deformation / Cracks / Signs of Wear / Corrosion
Main, Fwd. & Aft Spars Deformation / Cracks / Signs of Wear / Corrosion
Flaperon Deformation / Cracks / Signs of Wear / Corrosion
Hinges Smooth Operation / Play / Lubrication
Electrical Connections Corrosion / Damage
Stall Warning Secure / Connection / Condition
Fuselage Pin Latching Mechanism Test Operation and Warning Indication
Wing Retention Pins & Bushings Signs of Fatigue / Wear / Maximum I.D. 1.505 inch
Center Section (Channel & Bulkheads) Deformation / Cracks / Signs of Wear / Corrosion
Rear Spar Doubler Check for Gap
AOA System Plumbing Test for leaks (After reinstallation of wings, if
required)


Paperwork Completed
Record Findings Aircraft Log
Record Inspection Aircraft Log
Record Maintenance Aircraft Log
Notes and explanation of

discrepancies found:
End of inspection checklist


Electrical System Diagrams
Refer to P. O. H. or the Downloads Section under the Support tab of Van’s

Aircraft’s web site
www.vansaircraft.com


Rev: 3.8 Van’s Aircraft
3 VIEW Date: 12/12/22


Feedback Form
Owner: Name Phone: Number Aircraft: Model
Contact: Name Phone: Number Total Time Serial Number
Inspector: Name Phone: Number Engine: Model
Inspection: Date Storage: Inside/outside/etc Total Time Serial Number
Location: City State Country
Affected Parts:
Problem Description:


Chapter 19 - GLOSSARY
100-hr Comparable to an annual condition inspection, except that the
Inspection interval of inspection is 100 hrs of operation instead of 12 calendar
months. This inspection applies to LSA used for commercial
operations such as flight instruction or rental, or both.
A&P Airframe and power plant technician as defined in the U.S. by 14
technician CFR Part 65 or equivalent certification in other countries.
Approved Some aircraft maintenance may be performed by an "Approved
Owner Owner" found competent by Van's Aircraft. Approval will be for a
specific task, person(s) and aircraft.
F39 Refers to the FAA Advisory Circular ‘Acceptable Methods,
Techniques, and Practices – Aircraft Inspection and Repair.
Adverse Includes, but not limited to, conditions that could cause build up of
conditions foreign matter or contamination or removal of lubrications, such as;
extreme weather, and dirty, sandy or salty conditions, thorough
plane washing, etc.
Annual Detailed inspection performed once a year on an LSA in
Condition accordance with instructions provided in the maintenance manual
Inspection supplied with the aircraft and F39 Appendix D. The purpose of the
inspection is to identify any wear, corrosion, or damage before it
compromises the safe operation and airworthiness of the aircraft.
Anti- AST. The anti-servo/trim tab has two functions. It provides
Servo/Trim tab movement resistance (control force feed back), and also serves as
a trim control surface. The trim function is controlled with the pitch-
trim servo.
AOA Angle of Attack
As needed At first sign of wear or abnormal operation and/or following
exposure to adverse conditions.
CFR 14 Code of Federal Regulations Title 14 Aeronautics and Space also
known as the FAR’s.
Check To verify the correctness of, as by comparison to inspect or test the
condition, performance, safety, etc., of
Electronic EFIS. Refers to the Dynon D-180, Dynon Skyview or Garmin G3X.
Flight The unit receives signals from multiple sensors on the airframe and
Information engine and provides valuable engine and flight information based
System on the signals from the sensors.
Emergency ELT. The electronic device unit that sends a distress signal when G
Locating loads exceed a critical value, or when activated manually.
Transmitter

Engine EMS. Refers to the Dynon D-180, Dynon Skyview or Garmin G3X.
Management The portion of the EFIS unit that compiles and displays engine
System information.
Extreme Heavily contaminated air; dust, bugs, smoke, debris, ash, sand, etc.
conditions or adverse climatic conditions
Flaperon A control surface that combines the aileron and flap functions into
one component with both functions
Global GPS. A navigational system involving satellites and computers that
Positioning can determine the latitude and longitude of a receiver on Earth.
System
Heavy Maintenance, inspection, repairs, or alteration that a manufacturer
Maintenance has designated to require special training, equipment, or facilities.
Only a qualified person may perform heavy maintenance.
Kit Assembly KAI. Refers to the original kit assembly instructions that are
Instructions provided by the manufacturer to complete the assembly of a kit
plane.
Line Any repair, maintenance, scheduled checks, servicing, inspections,
Maintenance or alterations not considered heavy maintenance by the
manufacturer with instructions provided in the manufacturer’s
maintenance manual.
LSA LSA-RI. U.S. FAA- certified repairman (light sport aircraft) with an
Repairman inspection rating as defined by 14 CFR Part 65, authorized to
Inspection perform the annual condition inspection on experimental light sport
aircraft, or an equivalent rating issued by other civil aviation
authorities. This requires a 16-hour course.
LSA LSA-RM. U.S. FAA-certified light sport aircraft technician with a
Repairman maintenance rating as defined by 14 CFR Part 65. This certificate is
Maintenance authorization to perform line maintenance, inspections, and repairs
on any LSA certified aircraft. The maintenance rating is category
specific, I.E. Fixed wing, weight shift, lighter than air, etc.
Maintenance Manual provided by an LSA manufacturer or supplier that specifies
Manual(s) all maintenance, repairs, and alterations authorized by the
manufacturer.
Major Repair, Only a qualified person may perform major repair, alteration, or
Alteration, or maintenance tasks that are not included in this maintenance
Maintenance manual.
Manufacturer Any entity engaged in the production of an LSA or component used
on an LSA.
Minor Repair, Generally applies to repair, alteration, or maintenance covered by
Alteration, or instructions provided in the maintenance manual(s) supplied to the
Maintenance consumer.

Overhaul Maintenance, inspection, repair, or alterations that are only to be

accomplished by the original manufacturer or a facility approved by
the original manufacturer of the product.
Overhaul Facility specifically authorized by the aircraft or component
Facility manufacturer to overhaul the product originally produced by that
manufacturer.
Pilot Operating POH. The handbook provided with the aircraft that introduces the
Handbook systems and features that are included in the RV-12iS. Includes air
and ground operating procedures and defines performance and
weight and balance information.
Special Light S-LSA. Applies to the aircraft covered in this manual, provided it
Sport Aircraft remains consistent with the manufacturers design specifications.
Manufacturer design specifications are in accordance with ASTM
standards; F2245 for airplanes.
Repair Facility Facility specifically authorized by the aircraft or component
or Repair manufacturer to repair the product originally produced by that
Station manufacturer.
SPC Sport Pilot Certified
Sport Pilot SPC. A person who holds a current Sport Pilot Certificate. A
Certified certified sport pilot may perform some line maintenance as
described in FAR 43, appendix A, and approve for flight a private
use S-LSA aircraft that they own or operate.
Stabilator An aircraft control surface that combines the horizontal stabilizer
and elevator into one fully movable component.


Chapter 20 - INDEX
A
AOA (see Angle-Of-Attack)

Abbreviations .....................................................1-6
Air filter .............................................................12-3
Oil.................................................................1-11
Inspection.......................................................3-9
Installation....................................................12-7
Removal.......................................................12-7
Angle-Of-Attack Sys. Press. Check.........3-16, 5-13
Anti-servo / trim tab .................................... 5-6, 5-7
Inspection.....................................................3-11
Lubrication ...................................................5-27
Audio Input & Adjustment...................................9-7
Avionics ..............................................................9-1
Battery ................................................................8-5
Charging ......................................................8-12
Installation......................................................8-5
Removal.........................................................8-5
Bellcrank
Bearing...........................................................6-7
Stops ..............................................................3-5
Brake pedal
Lubrication .....................................................7-4
Brake Shoe Lining
Inspection..............................See Matco Manual
Replacement..................................................7-6
Brake System .....................................................7-1
Drain ..............................................................7-5
Flush ..............................................................7-5
Substitute Parts............................................17-2
BUDS .....................................See Troubleshooting
Canopy ...............................................................5-3
Cleaning.......................................................1-11
Installation....................................................5-14
Inspection.......................................................3-6
Latch Block .......................................... 5-3, 5-23
Removal.......................................................5-14
Capacities.........................................................1-13
Carburetor Bowl, Draining..............................13-15
Carburetor Synchronization .............................12-8
Center Section
Inspection.....................................................3-13
Cherry Rivet (see Rivet, Blind)
Cockpit

Inspection.......................................................3-5
Control cable ......................................................6-1
Replacement..................................................6-6
Control Stops .....................................................3-5
Control system ...................................................6-1
Rod-End Lubrication ......................................6-8
Coolant ................................................. See Engine
Cowl Hinge ........................................... 12-2, 12-11
Cowling
Installation....................................................12-5
Removal.......................................................12-5
Decorative paint ...............................................15-5

Dynon ......................................... 9-2, 9-3, 9-4, 18-3
Electrical System................................................8-1
Schematic ............................................ see POH
Emergency Locator Transmitter
Inspection.......................................................3-7
Empennage ........................................................5-6
Inspection.....................................................3-10
Engine .................................................... 1-12, 12-3
Firing Order..................................................12-4
Inspection.............................. See Rotax Manual
Lubrication
Coolant ....................................................12-7
Oil .................................................. 1-13, 12-6
Operating limits................. See Rotax Manual
Replacement..............................................12-13
Specifications........................ See Rotax Manual
Equipment List .................................................1-21
Exhaust System ...............................................14-1
Installation....................................................14-3
Lubrication ...................................................14-4
Removal.......................................................14-3
Feedback............................................... See Safety

Firewall Forward...............................................12-1
Inspection.......................................................3-8
Flaperon .............................................................5-4
Lubrication ...................................................5-26
Fuel Filter.........................................................13-3
Replacement .............................................13-14
Fuel Pre-filter....................................................13-3
Clean/Inspect ............................................13-13
Fuel Pressure Hose .........................................13-3
Flush..........................................................13-11
Fuel Return Hose .............................................13-3
Flow Check................................................13-12
Fuel System .....................................................13-1

Draining........................................................13-4
Fuel Tank .........................................................13-7
Installation....................................................13-8
Removal.......................................................13-8
Fuselage.............................................................5-2
Inspection.....................................................3-12
Lift and Support............................................1-16
Fuselage Pins ....................................................5-3
Fuses..................................................................8-6
Garmin.........................................................9-2, 9-4
Gascolator
Cleaning.......................................................13-9
Installation..................................................13-10
Inspection.......................................................3-6
Removal.......................................................13-9
Harness, Shoulder .............................................5-3

Inspection.......................................................3-6
Replacement................................................5-22
Heat......................................................See Utilities
Hinge
Cowl .......................................... See Cowl Hinge
Hinge
Anti-Servo Tab .............................................5-27
Flaperon.......................................................5-18
Rudder .........................................................5-19
Stabilator......................................................5-20
Idle Speed Setting............................................12-9

Inner tube
Main .............................................................5-16
Nose.............................................................5-17
Inspection ...........................................................3-1
Checklist ......................................................18-7
Landing Gear .....................................................5-8

Inspection.....................................................3-13
Lights..................................................................8-1
Lubricant...........................................................1-11
Lubrication........................................................1-13
Main Landing Gear

Bearings.......................................................5-28
Inspection.....................................................3-13
Installation....................................................5-22

Removal.......................................................5-22
Main Wheel and Tire
Inspection.....................................................3-13
Installation....................................................5-15
Removal.......................................................5-15
Main Wheel Assembly ...................................5-9
Master cylinder
Installation......................................................7-4
Removal.........................................................7-3
Nose Gear Leg Fairing.....................................5-10

Nose Landing Gear ............................................5-8
Inspection.....................................................3-13
Lubrication ...................................................5-28
Removal.......................................................5-22
Nose Wheel and Tire
Bearings.......................................................5-27
Installation....................................................5-16
Removal.......................................................5-16
Nose Wheel Assembly .......................................5-9
Oil ......................................................... See Engine

Overstress ..........................................................3-1
Paint ................................See Painting and coating

Painting and Coating........................................15-1
Pitch-Trim Servo
Replacement..................................................8-7
Pitot & Static.......................................................9-3
Powder coat
Repair ..........................................................15-3
Primer ..........................................................15-4
Propeller ...........................................................11-1
Inspection............................................. 3-7, 11-3
Push/pull cable .................................................10-3
Inspection............................................... 3-5, 3-9
Radio
Inspection.......................................................3-6
Rear Spar
Doubler Check .............................................3-15
Doubler Replacement ..................................5-24
Lubrication ...................................................5-26
Rivet
Blind, Cherry Max Alternative ........................4-2
Inspection.....................................................3-10
Rod end

Lubrication .....................................................6-8
Replacement..................................................6-7
Rudder Pedals
Installation......................................................6-8
Removal.........................................................6-8
Rudder................................................................5-6
Inspection.....................................................3-11
Hinge Replacement .....................................5-19
RV-12iS
3-View ........................................................18-31
Summary........................................................1-1
Safety .................................................................1-4
Feedback .....................................................17-1
Feedback Form..........................................18-33
Sensenich.......................................... See Propeller
Service Schedule ...............................................2-1
Table/ Checklist ...........................................18-3
Snap bushing ...................................................8-11
Software .............................................................9-6
Spark Plug........................................................12-4
Replacement................................................12-5
Stabilator ............................................................5-6
Control cable pulley .......................................6-3
Inspection.....................................................3-11
Storage, Long Term .......................................13-15
Stub Spar
Lubrication ...................................................5-26
Supplement ......................................................18-1
Substitute Parts ................................................17-3
Tire Air Pressures ............................................1-14

Torque ..............................................................1-15
Troubleshooting ...............................................16-1
Units ...................................................................1-7
Utility Systems..................................................10-1
Heat .............................................................10-2
Ventilation ....................................................10-3
Vent door .................................................10-4
Ventilation.............................................See Utilities
Vertical Stabilizer ...............................................5-6
Inspection.....................................................3-10
Volume ....................See Audio Input & Adjustment
Weight and Balance .........................................1-18
Wheel Assembly Balancing..............................5-29

Wheel Bearings
Main .............................................................5-28
Nose.............................................................5-27
Wing Attach Location Lubrication ....................5-26
Fuselage Pins ..............................................5-26
Stub Spar and Rear Spar ............................5-26

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Rev: 3.

8 Van’s Aircraft Date: 12/12/22

Aircraft Serial Number: ____________________

Printed copies are uncontrolled. i VAD-10005

THIS PAGE INTENTIONALLY LEFT BLANK

Printed copies are uncontrolled. ii VAD-10005

Rev Page Change Date

Printed copies are uncontrolled. iii VAD-10005

For continued airworthiness of an RV-12iS aircraft, the owner/operator must comply

 Each owner/operator of an RV-12iS shall read and comply with the

 Each owner/operator of an RV-12iS shall provide Van's Aircraft Inc. with up to

Van's Aircraft, Inc.

 An owner of an RV-12iS shall ensure that any needed corrective action be

 Should an owner/operator not comply with any mandatory service requirement

 The owner/operator may submit written comments and questions regarding

Printed copies are uncontrolled. iv VAD-10005

INTRODUCTION ............................................................................................................ 1-1

CHAPTER 2- SERVICE SCHEDULE .......................................................................... 2-1

CHAPTER 3- INSPECTION......................................................................................... 3-1

OVERSTRESS .............................................................................................................. 3-1

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Firewall Forward..................................................................................................... 3-8

CHAPTER 4 - STRUCTURAL REPAIRS .................................................................... 4-1

OVERVIEW .................................................................................................................. 4-1

CHAPTER 5 - STRUCTURES ..................................................................................... 5-1

OVERVIEW .................................................................................................................. 5-2

CHAPTER 6 - FLIGHT CONTROLS............................................................................ 6-1

OVERVIEW .................................................................................................................. 6-2

CHAPTER 7 - BRAKE SYSTEM ................................................................................. 7-1

OVERVIEW .................................................................................................................. 7-2

CHAPTER 8 - ELECTRICAL SYSTEM ....................................................................... 8-1

OVERVIEW .................................................................................................................. 8-2

CHAPTER 9 - INSTRUMENTS & AVIONICS .............................................................. 9-1

OVERVIEW .................................................................................................................. 9-2

CHAPTER 10 - UTILITY SYSTEMS .......................................................................... 10-1

OVERVIEW ................................................................................................................ 10-2

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VENTILATION ............................................................................................................. 10-3

CHAPTER 11 - PROPELLER.................................................................................... 11-1

OVERVIEW ................................................................................................................ 11-2

CHAPTER 12 - FIREWALL FORWARD.................................................................... 12-1

OVERVIEW ................................................................................................................ 12-2

CHAPTER 13 - FUEL SYSTEM................................................................................. 13-1

OVERVIEW ................................................................................................................ 13-2

CHAPTER 14 - EXHAUST SYSTEM ......................................................................... 14-1

OVERVIEW ................................................................................................................ 14-2

CHAPTER 15 - PAINTING AND COATINGS ............................................................ 15-1

OVERVIEW ................................................................................................................ 15-2

CHAPTER 16 - TROUBLESHOOTING ..................................................................... 16-1

CHAPTER 17 - FEEDBACK & REPLACEMENT PARTS ......................................... 17-1

REPORTING METHODS ............................................................................................... 17-1

CHAPTER 18 - SUPPLEMENT ................................................................................. 18-1

SERVICE SCHEDULE................................................................................................... 18-3

CHAPTER 19 - GLOSSARY...................................................................................... 19-1

CHAPTER 20 - INDEX............................................................................................... 20-1

Printed copies are uncontrolled. vii VAD-10005

NOTE: Pages 1-21/22 and 1-23/24 correspond to a particular EFIS installation.

Addendum Documents list (Notification, Service Bulletin, etc.)

Printed copies are uncontrolled. viii VAD-10005

Each owner/operator of an RV-12iS shall read and comply with the

Each owner/operator of an RV-12iS shall provide Van's Aircraft Inc. with up to

An owner of an RV-12iS shall ensure that any needed corrective action be

Should an owner/operator not comply with any mandatory service requirement

The owner/operator may submit written comments and questions regarding

WEIGHT ___ lb _ lb _____ lb

EMPTY WEIGHT = _ lb EMPTY ARM = inches