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http://jabiru.net.au/service/manualsAll manuals on this page can be searched by pressing Ctrl-F or ⌘-F, or alternatively select from one of the following categories:
Engine Maintenance Manuals
Engine Overhaul Manuals
Cold Start Installation
Maintenance Persons Information
Troubleshooting Strobe Systems
Engine Installation Manuals
Engine Parts Book
Propeller Manuals
Aircraft Technical Manuals
Pilot Operating Handbook
Standard Wiring Practices
Tail Pipe Fitting into Muffler Body for Non-Jabiru Airframes
Throttle Cable Kit
Airframe Constructors Manual
Card Diagrams
Click here for a list of avionics & instrument repair/calibration service centres in Australia.
Click here for owners/operators responsibilities for continued operational safety monitoring.
Engine Maintenance Manuals
Engine Maintenance Manual JEM0002-7 (Revision 7, June 2016)
J5100 Engine Maintenance Manual JEM5101-3 (Revision 3, June 2010)
Generation 4 Engine Maintenance Manual JEM0005-1 (Revision 1 October 2017)
Engine Overhaul Manuals
Generation 4 2200 / 3300 Overhaul Assembly and Parts Book JEM0004-1(Revision 1 January 2017)
2200 / 3300 Overhaul Manual JEM0001-12 (Revision 12 December 2017) CASA Approval Pending
Cold Start Installation
Cold Start Installation Instructions
Cold Starting Checklist
Maintenance Persons Information
Summary of Significant Engine Changes
Click Here for Procedure for Cylinder Head Modification for CHT Sensor Installation
Troubleshooting Strobe Systems
Trouble Shooting Strobe Systems
Engine Installation Manuals
J2200 Engine Installation Manual (Revision 8 October 2015)
J3300 Engine Installation Manual (Revision 7 December 2016)
J5100 Engine Installation Manual (Revision 1 June 2009)
Engine Parts Book
J2200 Hydraulic Lifter Engine
J2200 Roller Cam Hydraulic Lifter Engine
J2200 Solid Lifter Engine
J3300 Hydraulic Engine
J3300 Roller Cam Hydraulic Lifter Engine
J3300 Solid Lifter Engine
J5100 Solid Lifter Engine
Propeller Manuals
Propeller Technical Manual Issue 4 12th May 2014
2200 and 3300 Jabiru Scimitar Propeller Manual Issue 5, 8th June 2016
Aircraft Technical Manuals
J120, J160/170, J230 Aircraft Technical Manual Issue 8, 28th March 2017
CASA Approval for J160C Pending
Pilot Operating Handbook
J160-C
J160-D
J170
J230
J120
Standard Wiring Practices
Wiring Diagram All Models
Tail Pipe Fitting into Muffler Body for Non-Jabiru Airframes
Tail Pipe Fitting
Throttle Cable Kit
Throttle Cable Kit
Airframe Constructors Manual
Welcome to the Constructors Manual page!
In these Manuals you will find all the instructions that you will need to build your very own Jabiru, one step or task at a time. Each task in these Manuals stands alone, with the intention that each task will be completed before you move on to the next task. There are many good reasons for this approach: you can easily keep track of where you are in the build; it forms a checklist to ensure that nothing gets overlooked; and in many cases a task will be dependant on the completion of a previous task and if the sequence shown in the Table of Contentsis followed there will be no issues of this kind.
The Table of Contents of this Manual is also the Build Sequence.
The Constructors Manual is being written and updated on a continuous basis and the information on this page will be regularly updated. In all cases the version of each task or Manual is the date in the footer, where the latest date is the current version, so if you have downloaded a task and you want to check if there has been an update just check the date in the footer.
There are 6 model-specific Constructors Manuals listed below. They are reasonably large (~25MB) .pdf files that have been optimised for fast web viewing: click on them to view or download. Each Manual has a linked Table of Contents (ToC): click on any heading in the ToC to go directly to that task – this is a standard navigation feature in pdf files
If you only want a specific task and don’t want to view or download the model-specific files, then below the Constructors Manuals are all the individual tasks in the Constructors Manual, listed in the correct build sequence, all of which are small .pdf files of between 4 and 8 pages. Click on any task to view or download.
Model identification for the individual files: “J100” denotes J160 and J170, “J2400” denotes J230, J250, J430 and J450. “J2430” denotes J230 and J430, “J2450” denotes J250 and J450 and so on. “JALL” denotes all “J” series aircraft.
Regardless of which tasks you choose to view, we recommend that you start by reading the General Introduction before proceeding to the individual tasks. This contains important information and should be read thoroughly before and during your build.
Jabiru J160 Construction Manual
Jabiru J170 Construction Manual
Jabiru J230 Construction Manual
Jabiru J430 Construction Manual
Jabiru J250 Construction Manual
Jabiru J450 Construction Manual
Build Sequence for Kit Aircraft
General Introduction
Pre-Paint
Fuselage
Underbody penetrations_J2400
Fit ventral fin and trim horn_JALL
Prepare fuselage_J100
Prepare fuselage_J2400
Undercarriage
Undercarriage_Assemble main wheels_JALL
Undercarriage Assemble main gear/brakes J160
Undercarriage Assemble main gear/brakes J1702400
Undercarriage_Fit main gear J100
Undercarriage_Fit main gear_J2400
Firewall
Fit firewall_JALL
Firewall fittings_J100
Firewall fittings_J2400
Assemble and fit nose gear_J100
Assemble and fit nose gear_J2400
Fit engine and mount_J100
Fit engine and mount_J2400
Fit windscreen_JALL
Fit control cables and lines_J100
Fit control cables and lines_J2400
Empennage
Fit vertical tail fin J100
Fit vertical tail fin J2400
Fit elevator J160
Fit elevator_J170_2400
Fit horizontal stabiliser_J100
Fit horizontal stabiliser J2400
Fit Rudder J160
Fit Rudder J1702400
Engine
Fit propeller flange extension JALL
Fit ram air cooling ducts_J2400
Fit ram air cooling ducts_J100
Fit oil cooler J100
Fit oil cooler J2400
Fit cowling_J100
Fit cowling_J2400
Fit flap drive shaft mounts_JALL
Interior
Console - Pre-Fit Handbrake_JALL
Console - Pre-Fit Trim Control_JALL
Console - Fit Control Stick_JALL
Fit Rudder Pedal Mount Blocks_JALL
Fit aileron cable brackets J100
Fit aileron cable brackets J2400
Fuel System_J100
Fuel System_J2400
Fit seatbelt anchors_J100
Fit seatbelt anchors_J200
Fit seatbelt anchors_J400
Fit rear seat_J400
Pre-fit doors_J100
Pre-fit doors_J2400
Fit door gutters_J2400
Fit windows_JALL
Wheel Alignment_JALL
Pre-Fit wheel spats_JALL
Wings
General_JALL
Fit fuel tank filler body_J100_2430
Fit fuel tank filler body J2450
Prepare wing root J160
Prepare wing root J170
Prepare wing root J2430
Prepare wing root J2450
Cut aileron cable inspection opening_JALL
Fit quick drain sumps J160
Fit quick drain sumps J170 J2430
Fit quick drain sumps J2450
Mount flaps_J100
Mount flaps_J2430
Mount flaps J2450
Fit Wing tips_J160
Fit Wing tips_J170_2430
Fit Wing tips J2450
Fit Ailerons J1602400
Fit Ailerons J170
Fit pitot tube to strut JALL
Fit vibration damper to strut J1702400
Test Fit Wings JALL
Paint
Painting JALL
Post-Paint
Fuselage
General JALL
Fit Panel Mounted Throttle JALL
Assemble Instrument Panel JALL
Electrical Wiring Diagrams JALL
Fit Upholstery JALL
Install Electrical Wiring JALL
Interior
Fit console controls J160
Fit console controls J1702400
Fit rudder pedals J100
Fit rudder pedals J160
Fit rudder pedals J170
Fit rudder pedals J2400
Fit flap drive motor J100
Fit flap drive motor_J2400
Fit instrument panel housing JALL
Fit instrument panel JALL
Fit upholstery J100
Fit upholstery J200
Fit upholstery J400
Empennage
Fit rudder and elevator J160
Fit rudder and elevator J1702400
Fit doors J100
Fit doors J2400
Firewall Forward
Engine Control Cabling J100
Engine Control Cabling J2400
Fit Propeller and Spinner Composite JALL
Fit propeller and spinner Wooden_JALL
Connect cabin heater JALL
Fit Wheel Spats JALL
Wings
Install Aileron Cables J160
Install Aileron Cables J2430
Install Aileron Cables J2450
Fit Stall Warning J100
Fit Stall Warning J2400
Prepare wings for fitting J160
Prepare wings for fitting J170
Prepare wings for fitting J2430
Prepare wings for fitting J2450
Fit Wings JALL
Connect ailerons JALL
Connect wing tanks J100
Connect wing tanks J2400
Fit flaps J100
Fit flaps J2400
Fit fairings J100
Fit fairings J2400
Testing
General JALL
Weight and Balance J100
Weight and Balance J2400
Rigging Check JALL
Calibrate Fuel Gauges JALL
Fit Registration Marks JALL
Final Inspection Checklist J160
_Final Inspection Checklist J1702400
Flight Testing JALL
Flight Testing Forms JALL
Troubleshooting VHF Noises JALL
