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North Wing Sport X2 582 Maintenance Manual

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North&Wing&S,LSA&Maintenance&Manual&
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Issue 3.2
Model:&Sport&X2&582&
North Wing UUM, Inc.
103 Gala Ave Chelan, Wa. 98816
USA
+ 509-682-4359
+ 509-682-0758
www.ultrikes@northwing.com
Printed: July 16 2017
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Summary of Contents for North Wing Sport X2 582

  • Page 1 North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& Manufacturer: North Wing UUM, Inc. 103 Gala Ave Chelan, Wa. 98816 Phone : + 509-682-4359 Fax : + 509-682-0758 Website : www.ultrikes@northwing.com Issue 3.2 Printed: July 16 2017 Page 1...
  • Page 2 Model:&Sport&X2&582& Preface The documents listed below are required for a complete S-LSA package for the North Wing Apache 582 S-LSA. This document is the North Wing S-LSA Sport X2 582 Maintenance Manual for Types Navajo and Apache. It describes the maintenance requirements and procedures for the wing, carriage, engine, and propeller.
  • Page 3 June -2015 Maintenance June 2015 Kamron task added Blevins Table&1&Amendment&Record&Sheet&! NOTE: North Wing’s manuals will be revised as necessary. Registered North Wing S-LSA owners will notified changes directed North Wing site Issue 3.2 Printed: July 16 2017 Page 3...
  • Page 4 North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& (<http://www.northwing.com>) for the applicable pages. The amended pages should be printed and the prior page replaced in the folder as soon as possible. The amendment table should at that time be updated with the appropriate details and date. Issue 3.2 Printed: July 16 2017 Page 4...

  • Page 5: Table Of Contents

    North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& Table&of&Contents& 1.0 Introduction ........................7 1.1 Skills .......................... 7 1.2 Prohibited Maintenance and Alterations ..............8 1.3 Tooling and Materials ....................9 1.4 Service Difficulties and Errors ..................9 1.5 Format ........................10 1.6 Mandatory Service Bulletins ..................10 2.0 General Information....................
  • Page 6 North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& 4.3.3 Replace Rear Tire ....................54 4.3.4 Replace Rear Wheel Bearing................56 4.3.5 Replace Rear Brake Pads, Calipers, and Disc, and Bleed Brakes ......57 4.3.6 Replace Front Tire ..................... 61 4.3.7 Reposition Front Fork Assembly ................ 63 4.3.8 Repair/Replace Front Fork Assembly ..............

  • Page 7: Introduction

    1.0& Introduction& This manual contains factory recommended procedures and instructions for ground handling, inspection, servicing and maintaining the North Wing S-LSA aircraft. The procedures described are to be used in conjunction with the appropriate Airworthiness Authority of the country of registration.

  • Page 8: Prohibited Maintenance And Alterations

    Repairman Maintenance technician for Rotax engines. A list of Rotax repair stations can be found on-line, or contact your North Wing dealer. Although “repairs” may be authorized for nearly all components, ”alterations” to the following...

  • Page 9: Tooling And Materials

    Any service difficulties, errors in this manual, or product defects should be reported to North Wing via the web site, fax, or telephone. Corrections will be made as appropriate and reported on the North Wing UUM Inc. web site. Issue 3.2...

  • Page 10: Format

    The information in this manual is based on the data that was available at the time of its publication. The latest amendments to this manual will be issued on the North Wing website in PDF format. This should be printed out and added to the manual. Therefore it is important that operators keep a regular check on the website for any amendments that have been made.

  • Page 11: General Information

    North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& 2.0& General&Information& 2.1# Specifications# 2.1.1& Wing (Mustang III- 15) For other Wings refer to the Wings owners manual •! Surface area: 161 sq.ft. •! Weight: 115 lbs •! Leading edge tube distance from the nose plate anchor hole to: 1.
  • Page 12 North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& 2.1.2& Carriage Standard Configuration: Material: •! Root tube: 2” x 3” rectangular 6061 aluminum tube •! Seat frame: 1¼ inch outside diameter 6061 aluminum tube •! Welded steel lower back frame •! Welded steel dual mast •! 1 inch diameter 6061-T6 aluminum nose tube with machined aluminum fittings at both ends for attachment •! 2”...

  • Page 13: Fuel System

    •! Exhaust silencer •! E-box gear drive (3.47/1 ratio) with electric start •! North Wing custom dual radiator system •! 93.1 lbs with exhaust, carburetors, silencer. w/o fuel pump or radiator •! 64 hp @ 6500 rpm; 55ft.lbs max torque @ 6000 rpm •! 6800 max rpm...
  • Page 14 North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& •! Coolant: 50/50 Ethylene Glycol/Water mix •! Coolant capacity: 1.2 gal US •! Single dual acting thermostat in engine opens at 135°F 2.1.6& Propeller •! Warp 3 blade 72” carbon fiber propeller •! Pitch set by gauge 2.1.7& Electrical&System& Standard Configuration: •! Ignition system (see engine) •! 12 volt starter with key operation from the front seat...
  • Page 15 North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& 2.1.9& Torque Specifications and Securing Before any fastener is torqued to specifications, it is important to assure at least one full thread of the bolt will extend beyond the nut when tightened. If the nut does not extend at least that far, the bolt thread itself may fail if tightened to specifications.

  • Page 16: Carriage

    North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& Location Size Securing Torque Method Value (inch lbs) Carriage: Rear wheel axle nut 5/8” Nylock Snug –1/4 turn Front wheel axle nut 5/8” Nylock Snug –1/4 turn Split wheel rim bolts 1/4” Nylock Snug Axle to backframe bolts thru fiberglass rods 1/4”...

  • Page 17: Cooling System

    North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& Location Size Securing Torque Method Value (inch lbs) Cooling System: Radiator mounting bolts 5/16” Lock washer Snug Hose clamps As required to prevent leaking Wing: Base tube left side connections to corner 1/4” Castle bracket Base tube right side connections to corner 1/4”...

  • Page 18: Weight And Loading

    North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& 2.2# Weight#and#Loading# •! Maximum Gross Weight: 1060 lbs •! Empty weight w/o options o! Navajo 450 lbs o! Apache 490 lbs •! Useful load: 500 lbs •! Maximum Fuel weight (17 gals): 105 lbs •! Pilot, Passenger, baggage @ full fuel: Apache 395 lbs The trike center of gravity (CG) is adjusted by sliding the pivot block retaining collars forward and aft to the desired position.

  • Page 19: Ground Handling

    North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& block assembly with very little manual force. Retighten the collar bolts evenly. DO NOT tighten just one collar bolt completely and then the other. This will distort and possibly damage the keel tube. Hang Point Moved Full Forward Hang Point Moved Full Back Collar Bolts ¼”...

  • Page 20: Parking And Tie Down

    All original equipment replacement parts for the carriage, propeller, and wing are available direct from North Wing through your Regional North Wing dealer. In most cases, all parts are in stock for immediate delivery. Rotax engine parts are available only through authorized Rotax parts dealers or repair stations.
  • Page 21 North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& There are very few disposable replacement parts on the North Wing S-LSA trike, however, wear and consequential replacement is expected on some parts. The following table indicates those parts expected to be replaced on a regular schedule or as a result of regularly scheduled inspections.

  • Page 22: Inspections

    North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& 3.0& Inspections& All S-LSA aircraft must undergo an annual condition inspection by a qualified Repairman with at least a Maintenance rating (LSR-M). This requires satisfactory completion of an FAA approved 104-hour Repairman-Maintenance class for Weight Shift Control. In addition, anyone with an A&P certificate may perform the inspections.
  • Page 23 North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& 8.! Run engine at maximum RPM to check for proper propeller pitch. Acceleration should be smooth and achieve maximum RPM in 3 seconds or less. Failure to reach an indicated maximum speed between 6300 – 6500 RPM could be caused by excessive propeller pitch, fuel supply problem, carburetor adjustment, faulty tach, or an ignition problem, in order of their probability.

  • Page 24: Inspection Checklists

    North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& 3.2# Inspection#Checklists# North Wing Annual and 100-hour Inspection Check List Page 1 Pre- and Post-Inspection Run-up Date__________________________ Make_____________________ Model__________________ Serial Number________ Owner_________________________________________________________________ Type Inspection______________________________ Tach Time__________________ Total time________________ Completed Pass Fail Step 1.! Check logbook and operating limitations.
  • Page 25 North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& North Wing Annual and 100-hour Inspection Check List M-Pulse 15 Wing Pass Fail Perform the following checks on the wing For wing inspection it will be necessary to remove the wing from the trike and perform checks 1 – 15 with the sail on the frame. Then the sail should be removed from the frame to complete the wing inspection, items 16 &...
  • Page 26 North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& North Wing Annual and 100-hour Inspection Check List (continued) Carriage Pass Fail Perform the following checks on the trike carriage 1.! Confirm the required placards are in the proper places and readable: - Passenger Warning - “EXPERIMENTAL” is visible upon passenger entry...
  • Page 27 100-hour inspections. The Repairman performing the inspection shall refer to the details in the Rotax Maintenance Manual provided with the North Wing trike for any questionable items. 1.! Spark plugs for wear and indication of improper fuel mixture 2.! All engine head bolts for torque to those given in the Rotax...
  • Page 28 29.!Exhaust gas temperature probes are not physically damaged 30.!Manual starter rope in good condition and recoil mechanism works properly North Wing Annual and 100-hour Inspection Check List (continued) Propeller (Warp 3-Blade) Pass Fail Perform the following checks on the propeller 1.! Mounting bolts for proper torque...
  • Page 29 EGT readings, this could be caused by loose EGT connections, bad probe, faulty gauge, or carburetor adjustment or malfunction. North Wing Annual and 100-hour Inspection Check List (continued) Operational Inspection Pass Fail Perform the following operational checks 1.! Fuel pump...

  • Page 30: Maintenance And Repairs

    This manual describes the maintenance tasks listed in the following table that can be performed on the North Wing S-LSA trike Model: Sport X2. Some tasks can be performed by the owner with conventional tools, while others require special certifications as described in Section 1.1 above or special tools which are identified in the task description.

  • Page 31: Sail Tears Greater Than 1" Long

    North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& 4.! Sail tear greater than 1” long Factory repair or NW approved professional sail repair shop 5.! Sail removal from frame LSR-M, A&P 6.! Leading edge replacement LSR-M, A&P 7.! Keel tube replacement LSR-M, A&P 8.! Crossbar replacement LSR-M, A&P 9.! Front and rear pitch cable (lower rigging) LSR-M, A&P...
  • Page 32 North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& 7.! Replace starter solenoid – Out or Inside hot box LSR-M, A&P 8.! Connecting 12 Volt Power to Auxiliary Equipment LSR-M, A&P Engine: Section 4.6 1.! Changing Spark Plugs Owner, LSR-M, A&P 2.! Changing Gearbox oil Owner, LSR-M, A&P 3.! Remove and Replace prop.
  • Page 33 North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& 4.2# Wing#Maintenance:#MOPulse#15#Meter#Wing# 4.2.1& Wing Cleaning Skill Level: Owner and higher Tools: Damp cloth, pail, soft brush Materials: Water and possibly mild detergent, aluminum polish/cleaner, WD40 Task Description: The sail fabric should be cleaned regularly with a soft damp cloth. If the wing is exceptionally dirty, it can be washed with a mild detergent only.
  • Page 34 Adjustment” can be made. The code letters in the columns refer to the list of Corrective Adjustments in the following Table 4.2-2: Wing Corrective Adjustments. If neither of these two adjustments correct the problem, contact a North Wing dealer. Issue 3.2 Printed: July 16 2017...
  • Page 35 North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& Symptom Adjustment Adjustment Tail heaviness (flies too slow) Nose heaviness (flies too fast) Wing pulls to the right with hands off straight and level flight Wing pulls to the left with hands off straight and level flight Yaw unstable (roll response lag) Roll is unstable (difficult to keep from rolling) Roll too stable (heavy force required to enter into roll) Wing Breaks to left in a stall...
  • Page 36 North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& Code Description of Corrective Adjustments Move hang block back (1/2” at a time) Move hang block forward (1/2” at a time) Increase camber on the last 2 cambered left tip ribs by ¼”, or decrease the same on right tip by ¼” Increase camber on the last 2 cambered right tip ribs by ¼”, or decrease the same on left by ¼”...
  • Page 37 Since this is a very delicate task, this must be done by a North Wing dealer. Contact North Wing to find the nearest location to you where this can be done.
  • Page 38 North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& Leading Edge Tension Adjustment cont’d: Step 3: Using the black strap attached to the sail, Step 2: Loosen both trim tip screws 4-5 full pull the yellow strap out of the groove in the trim turns. Using the Philips screwdriver, “pop” the tip.
  • Page 39 North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& Wing Twist (Adjustments Q and R): Twisting the wing is done by loosening the wing trim tip and then simply twisting the sail at the tip by hand to a new position. The operation of the wing trim tip is described below. It is also helpful to review the description of “Inserting Shims”...
  • Page 40 Sail tears longer than 1”, or tears that are within 1” of an edge or seam must be repaired by a certified sail repair shop or returned to North Wing for repair. In most cases, the sail must be removed from the frame and shipped to the sail repair shop. For instruction on sail removal, see Section 4.2.5.
  • Page 41 North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& 4.2.5& Sail Removal from Frame Skill Level: LSR-M, or A&P Tools: Two 7/16” wrenches, one 9/16” wrench, Phillips screw driver, preferably a second person Materials: None Task Description: The sail should be removed for inspection of the frame every 3 years or 200 hours, OR if the wing has experiences any type of hard impact e.g.
  • Page 42 North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& 6.! Remove Philips screw holding sail in place at nose on each side located up near nose on leading edge. 7.! Remove rear wires from keel tube noting order of washers and saddles. 8.! Unzip crossbar/leading edge inspection zipper and remove crossbar attachment bolts on both sides.
  • Page 43 North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& 11.!Pull the sail out and over the top of the leading edge and the outside of the entire frame as shown below. Pull sail up and over top of frame on both sides 12.!Bring wing tips together again being careful not to force them. If any resistance is encountered, stop and check that the sail is clear of all parts, especially the tensioner cable attachments.
  • Page 44 North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& the mylar will buckle and bind as it is pushed in. Be sure the mylar is oriented properly with the relief cuts on the bottom side. Lay the mylar out straight on the ground aligned with the LE pocket that it will be going into. Slide the mylar into the LE “MYLAR POCKET”...
  • Page 45 North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& 2.! Remove the Philips screw from the damaged leading edge near the nose and save to re- install. 3.! Pull the white velcro straps at the wing tips apart that hold the sail leading edge tight against the leading edge tube. 4.! Pull the yellow sail retaining strap at the wing tip out of the trim cap groove using the loose black finger strap running parallel to the yellow strap but slight longer.
  • Page 46 North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& Rear section of LE separating from front section 10.!Once the rear LE section is removed, the rear sprog assembly can be removed by pulling the sprog out of its socket a sufficient distance to cut the bungee cord that pulls it in and then pushing the socket out of its hole in the leading edge.
  • Page 47 North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& 13.!Slide the nose section out through the crossbar zipped opening in the sail. 14.!Slide the rear section together with the nose section and check for any bends by rolling the assembled LE on a large flat surface and viewing down the tube while supported at several points on a flat surface.
  • Page 48 North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& 5.! Roll the wing onto its back so the bottom of the wing is facing up. Spread the wing tips out until the wing is about one quarter open. 6.! Remove rear cable assembly and tensioner hook assembly at the rear of the keel tube. 7.! Remove both trike collars by removing both Allen bolts from the collar halves.
  • Page 49 North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& 3.! Disconnect the nose wires from the swan hook and lay the wing flat on the ground with top of wing up. Pull the washout tubes out of their sockets and fold back toward the tips. Fold the sprogs back toward wing tips. 4.! Bring wing tips together simultaneously (requires 2 people) or in 3-4 small stages (if only one person) being careful not to force them together.

  • Page 50: Front And Rear Pitch Cables (Lower Rigging) Replacement

    North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& Crossbar center plate Crossbar center plate bolts looking from back side looking from front side Re-assembly Note: When re-assembling, remember to use a safety pin or ring on the castle nut on the crossbar attachment to the leading edge bracket. 4.2.9&...

  • Page 51: Replacing Wing Fittings And Hardware

    North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& Pitch cable attachment to downtube 3.! Remove cable attachment bolt at rear of keel tube. This is one of the two bolts that retain the tensioner hook to the keel tube. Inspect the bolt and replace bolt and nut if any signs of wear on the bolt.

  • Page 52: Carriage Maintenance

    North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& Task Description: Wing fittings and hardware include the following items: •! Nose plates •! Cross bar plates •! Crossbar to leading edge attachment hardware •! Sprog attachment hardware •! Front swan hook attachment •! Pull back cable attachment hardware In all cases replacement of this hardware requires the removal of the wing from the trike.

  • Page 53: Remove Rear Wheel Pants

    North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& clear water. Avoid wetting electrical wires and connections, air filter, and throttle, choke, and BRS cables by protecting with a plastic cover. Avoid spraying WD-40 or other degreaser on air filter, fabric side bags, wing fabric, electrical components, or metal components when they are hot.

  • Page 54: Replace Rear Tire

    North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& Long wheel pant bolt (1/2”) 3.! Lift wheel pant out of bolt holes on back side and off of wheel. Lift pant out of bolt holes 4.3.3& Replace Rear Tire Skill Level: Owner, LSR-M, A&P Tools: 1-1/8” Socket , two 7/16” wrenches, 3/8” Hex wrench, ½” socket Materials: Replacement tire, inner O-rings Task Description:...
  • Page 55 North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& Block under wheel pants mounting plate on both sides 3.! Remove large nut on end of wheel with 15/16” socket. DO NOT remove six smaller bolts. Wheel is a tubeless split hub and the two halves are held together with these six bolts.

  • Page 56: Replace Rear Wheel Bearing

    North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& Stopping pins slide into brake disc holes as shown above 5.! With wheel removed from axle, remove the six 5/16” bolts holding the split rim together. The plate holding the brake stopping pins will also be removed when these bolts are removed.

  • Page 57: Replace Rear Brake Pads, Calipers, And Disc, And Bleed Brakes

    North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& Task Description: 1.! Remove wheel as described in Section 4.3.3 above. 2.! It is NOT necessary to separate the rim halves. 3.! Using a long drift pin, reach in from one side and tap the bearing out of its seat by tapping around the circumference of the outer bearing race.
  • Page 58 North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& 3.! Loosen the two 1/8” hex set screws securing the caliper on the spindle. If the caliper is being replaced or serviced, slide the caliper off the spindle. Since the caliper is keyed onto the spindle, it may be necessary to bump the caliper off the key with a mallet. If the caliper is NOT being replaced or serviced, slide it just past the key so the bolts on the back side can be removed in subsequent steps.
  • Page 59 North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& 3 button head hex screws: Note! Center screw is fine thread. 6.! Remove the two 5/32” hex screws from the inboard side of the caliper and place screws and springs aside. Remove old pads, install new ones, and replace the hex screws. Keyed brake hub Hex head cap screws for inboard...
  • Page 60 North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& the spindle, the bleeder valve is on the side and some air will be trapped at the top of the chamber in the caliper. Although bleeding in this position still results in adequate braking, better braking can be achieved if the caliper if rotated. Therefore, it is best to bleed the brakes with the caliper just off the key so the bleeder valve can be rotated to the lowest point.

  • Page 61: Replace Front Tire

    North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& 9.! Move the pump/syringe to the caliper on the other side and repeat the bleeding procedure above. However, this time continue pumping fluid until no bubble can be seen coming out of the master cylinder. 10.!Close both bleeder valves and slide calipers back on key. While holding the key in keyway, line up slot in caliper and tap caliper back into place.
  • Page 62 North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& Support nose wheel off ground using sawhorses and rope under root tube 2.! Remove the nut from the front axle bolt using a 15/16” wrench and socket. Pull the axle bolt out of the drag link suspension arms being careful to support the wheel as it comes loose.

  • Page 63: Reposition Front Fork Assembly

    North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& 6.! Mount inboard rim on new tire 7.! Put seal disk with O-rings onto inboard rim. 8.! Align inboard half rim bolt holes with outboard rim and re-assemble rim. Torque rim bolts to specified values in torque table. 9.&...
  • Page 64 North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& 1.! Chock rear wheels on both front and rear sides of both wheels. Raise the front wheel off the ground at least 2” and support using saw horses as described in Section 4.3.7 above. 2.! If the trike has an instructor steering link, remove the bolt located mid-way on the connecting tube to allow the inner tube to slide inside the outer tube as the fork assembly in moved.

  • Page 65: Repair/Replace Front Fork Assembly

    North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& 4.3.8& Repair/Replace Front Fork Assembly Skill Level: LSR-M, A&P Tools: Hex wrenches Materials: Replacement parts Task Description: If the fork assembly is bent or twisted as may occur on a very hard landing, the fork arms or top or bottom plates will have to be replaced as described below. Other parts connected to the fork assembly can be replaced directly without having to remove the entire fork assembly.

  • Page 66: Repair/Replace Seat Frame And Front Seat Backrest

    North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& 4.3.8A REPLACING FRONT FORK TO 2016 TRIPLE TREE COMPLETE ASSEM. Task Description: 1. On the old fork disconnecting the Steering stabilizer, brake line and throttle cable. 2. Remove the older front fork by removing the center pivot bolt (see picture about) 3.
  • Page 67 North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& Corner hold down straps looking from underneath Note strobe light electronics mounted under seat plate 6.! Remove the lower bolts attaching the front seat backrest post to the root tube. 7.! Remove the hold down bolts attaching the rear metal seat plate to the crossbar shown below.
  • Page 68 North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& Fairing attachment screws 2 each side 11.!Pull the fairing just slightly clear of the metal anchor plate and prop in position with wood block or other soft material. 12.!Remove two ¼” bolts from top back of seat frame where it is attached to the backframe.
  • Page 69 North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& Lower front attachment bolts to root tube Support straps for front seat metal plate 14.!Lift seat frame out of trike and repair or replace. 15.!When re-assembling, if the web strapping running from the top back of the seat frame to the middle cross bar of the frame is removed, it must be re-installed at the correct length.

  • Page 70: Replace Main Dual Mast

    North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& 4.3.10& Replace Main Dual Mast Skill Level: LSR-M, A&P Tools: Two ½” wrenches Materials: Replacement parts Task Description: If the main mask is bent or damaged, it must be replaced as follows. 1.! Remove wing from trike. 2.! Release mast hold down so that mast is in full upright position. 3.! With mast in upright position, unbolt pneumatic cylinders from mast end and rotate cylinders clear of mast 4.! With help from a second person, remove the pivot bolts from the bottom of the mast on...

  • Page 71: Replace Mast Lift Cylinder

    North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& Front seat belt attachment point 4.! Unbolt rear seat belt tangs from backframe using two 7/16” wrenches. Rear seat belt attachment point 5.! Replace with new belts. 6.! The front seat shoulder harness straps (2) are fastened to the lower portion of the backframe.

  • Page 72: Replace Engine Mount Tubes

    North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& 1.! Remove wing from trike. 2.! With mast in full upright position, unclip and remove the pin at lower end of cylinder. Pin Clipped Pin Unclipped 3.! Unbolt the upper end of the cylinder at the mast. 4.! Replace with new cylinder. 4.3.13&...

  • Page 73: Repair Radiator Or Hose Leak

    North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& 4.3.14& Repair Radiator or Hose Leak Skill Level: LSR-M, A&P Tools: Standard metric wrench set, Philips screw driver, wire cutters, Materials: Replacement parts Task Description: Radiator leaks can be deceptive. A leaking hose fitting can allow coolant to run down unnoticed to a spot on the radiator and make it appear as if the radiator is leaking.
  • Page 74 North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& 3.! Remove fairing trim by gripping trim and gently pulling straight off. Do not pull on the portion of the trim that is already off like a rope to peel off the remaining attached portion. This will stretch the trim and possible tear it making remounting difficult. 4.! To remove the side panels, remove the two screws on upper rear of side panels.
  • Page 75 North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& Mounting bolts (4 on each side) 8.! Install drag struts and side landing gear (Gas Spring) strut. (Section 4.3.6) Tighten all 8 nuts to snug. Landing Gear Drag Strut 4 bolts each side 9.! Install rear wheels. (See section 4.3.3.) Use zip ties to secure the brake lines along the back of axles as shown in above picture.
  • Page 76 North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& 4.3.17& Remove and Replace Alum Leaf Spring Gear Skill Level: Owner, LSR-M, A&P Tools: 9/16, 1/2”, 7/16” and 3/8” wenches. Wheel nut socket Materials: new leaf spring 1.! Left the trike using blocks or a jack. Only do one side at a time. 2.! Remove the tire and breaks.
  • Page 77 North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& Mounting bolts (4 on each side) Fuel pump on rear holes 6.! Install rear wheel spindles into the spindle bracket. Install the bolt and nut to secure the spindle in place. (See section 4.3.3.) Use zip ties to secure the brake lines along the back of axles as shown in above picture.
  • Page 78 North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& Spindle bolt 4.3.18& Remove and Replace Root Tube Skill Level: Owner, LSR-M, A&P Tools: 9/16, 1/2”, 7/16” and 3/8” wenches. Wheel nut socket Materials: New Root Tube Tools#and#Supplies#Needed# ¼” Drill Bit, “F” (oversize) Drill Bit, Open-End Wrench Set. Assembly#Notes#–#Connect#Front#Root#Tube#to#Main#Root#Tube# 1.
  • Page 79 North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& Main&Root&Tube&to&Back&Frame&Assembly& Tools#and#Supplies#Needed# ¼” Drill Bit, “F” (oversize) Drill Bit, Open-End Wrench Set. Assembly#Notes#–#Connect#Main#Root#Tube#to#Back#Frame# Refer to “Leaf Spring To Frame” diagram and parts list for exploded parts view. 1.! Set rear end of Main Root Tube between center supports on Back Frame. 2.! Insert Delrin spacer into rear of Main Root Tube.
  • Page 80 North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& 4.4# Fuel#System#Repairs# The fuel system schematic is shown below. The fuel tank is a 15 gallon polypropylene tank designed to straddle the root tube. An aircraft style drain valve allows removal of a sample of fuel to assure no water is present in the tank. An equalizer line, located slightly above the bottom of the tank to avoid picking up contaminants, balances the level of fuel in the left and right halves.
  • Page 81 North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& 4.4.1& Replace Fuel and Pulse Lines Fuel lines harden with time and exposure to sunlight leading to cracks and leaks and a possible fire if fuel leaks onto hot surfaces. The pulse line is exposed to a milder environment than fuel lines since it is shielded somewhat from sunlight and does not carry liquid fuel.
  • Page 82 North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& 4.4.2& Replace Fuel Filter Skill Level: LSR-M, A&P Tools: Knife, pliers or wire twist pliers Material: Replacement filter with ¼” inlet and outlet lines, clamps or safety wire Task Description: Since the fuel filter should be replaced every 100 hours, this is a good time to check the fuel lines also.
  • Page 83 North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& a.! feed line from the filter b.! supply lines to each carburetor 3.! Remove the pulse line from the back of the fuel pump 4.! Again, if any of the lines are difficult to remove, cut them off and replace them. 5.! Connect the fuel lines and pulse line being careful of the routing so the pump can be returned to its original position under the main mast.
  • Page 84 If the drain valve shows any sign of leaking, check to determine if it is the valve or the tank that is leaking. If it is the valve, it should be replaced by a North Wing supplied drain valve. 1.! Drain all fuel from the tank and put in clean container if intended to be put back in fuel tank after repair.
  • Page 85 North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& two important facts If the fuel gage must be removed for the EMPTY calibration, there a to keep in mind: 1.! The 5 retaining bolts shown in the above picture are NOT in a symmetrical pattern. Therefore, the gasket and the inside ring that the screws attach to line up only one way. You need to plan on that when re-installing the gage.
  • Page 86 North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& Turn on the ignition switch. Turn the FULL and EMPTY adjustment screws located on top of unit to the full CW (clockwise) position. Setting The “Empty “ Point Setting the “Empty” must be done with the probe out of the tank or when tank is empty.
  • Page 87 North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& 4.5# Electrical#System# The wiring schematic for the electrical system is shown on the following page for the Apache 582 model. The Rotax 582 engine outputs a maximum of 170 watts of electrical power from the lighting coils inside the engine. These coils produce a crude AC power source that must be rectified and regulated by the Key West Rectifier/Regulator mounted on the side of the Hot Box.
  • Page 88 North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& Issue 3.2 Printed: July 16 2017 Page 88...
  • Page 89 Wht$22$GA$ From$Water$ Temp$sender$ EGT$&$CHT$pre5wired$cable.$ Nav$Lights$ Strobe$Lights$ EIS$25$pin$plug$ See$EIS$cable$diagram$ Gray$22$GA$Tach$wire$ Blk$16$GA$ Red$22$GA$ Starter$solenoid$ EIS$ internal$to$Hot$Box$ Hot$Box$Leads$to$Engine$ $$$5$Mag$1$ $$$5$Mag$2$ $$$5$Tach$ 10a$ 10a$ Red$16$GA$ EIS$Power$ $$$5$Ground$ Warning$ 20a$ To$Engine$ Mag$1$ Yel$14$AWG$ lighting$ coils$ Yel/Blk$14$AWG$ To$Starter$ Mag$2$ Red$6$AWG$ Blk$16$GA$to$ Hot$Box$Case$ off$ Red$6$AWG$ Mag$1$ Master$ Battery$ 12$volt$ Optional$...
  • Page 90 EIS EGT and CHT Probe Connections to Pre-Wired Cable Issue 3.2 Printed: July 16 2017 Page 90...
  • Page 91 North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& 4.5.1& Replacing Battery Skill level: Owner and higher Tools: Philips screw driver, 5/32” wrench Parts: Replacement battery Task Description: Battery technology for ultralights uses a sealed dry cell 12 volt battery that cannot be serviced. However, it will become discharged after extended periods of non-use and can be charged for continued service.
  • Page 92 North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& 5.! Lift battery straight out of the support plate and replace with new battery. 4.5.2& Checking and Replacing Voltage Regulator Skill level: LSR-M, A&P Tools: Philips screw driver Parts: Replacement Key West Regulator Task Description: The voltage regulator is attached to the side of the Hot Box as shown below. It can be tested using the procedure below.
  • Page 93 Replacement Switches or wire connectors Task Description: The North Wing Apache may have one set of mag switches (2 switches) or two sets (four switches). The second set is optional and would only be used when the aircraft is intended to be used for instruction.
  • Page 94 Fuel shut offs are not provided on North Wing aircraft because of the high probability of someone forgetting to open it but still having enough fuel in the carburetor to get off the ground.
  • Page 95 North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& 4.5.4& Testing and Replacing Master Switch Skill level: LSR-M, A&P Tools: Philips screw driver Parts: None Task Description: The Master switch provides power to the instruments and other accessories and is used to start the engine. Unlike an automobile switch, it does NOT affect engine “ignition” in any way. Any of the following symptoms may occur with a faulty Master switch: 1.! The EIS will not be operational when the switch is in the on position.
  • Page 96 North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& Two different starters are used depending upon whether a clutch is used in the drive system or not. The standard Rotax configuration is “without” a drive clutch. In this case the starter is integral to the Rotax E-box drive system. For engines with a clutch installed, a GPL aftermarket starter in installed on the electrical end of the engine adjacent to the manual pull started instead of at the PTO end of the engine.
  • Page 97 North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& Replacing the GPL aftermarket starter: 1.! Repeat Steps 1 and 2 above for the Rotax starter. 2.! Remove the bolts holding the starter in the GPL starter ring, and lift the starter out of the housing. 3.! Inspect the gear teeth on both the starter and the starter ring inside the housing. 4.! If the gear teeth on the starter ring gear are damaged, remove the manual pull starter.
  • Page 98 North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& Task Description: It is necessary to open the Hot Box to reach the starter solenoid. Therefore, be sure the starter solenoid needs replacement before beginning this task. If it is clear the solenoid has failed, then replace using the following procedure. 1.! Remove the Hot Box following the steps above in Replacing the Hot Box.
  • Page 99 North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& Hot Box Accessory Terminals: 1 three terminals in middle terminal strip Note from the electrical schematic above that only the first three terminals on the middle terminal strip are connected to a fused power supply. Any wires connected to the Hot Box should use a good crimp-on loop or open-loop connectors to slide under the terminal screw of the desired power tap.
  • Page 100 BRS manual. All tasks associated with the BRS can be performed by a conscientious and mechanically adept owner. The BRS mounting plate on the North Wing trike is located at the lower back of the root tube as shown below. Issue 3.2...
  • Page 101 North&Wing&S,LSA&Maintenance&Manual& Model:&Sport&X2&582& The BRS canister bracket is a white flanged bracket with a ring of holes. The recommended mounting arrangement for the BRS on an Apache is to aim the chute to the left. To attach the bracket to the trike mounting plate, follow the procedure below. 1.! Align two of the holes in the BRS bracket with two of the holes on the trike mounting plate and install a bolt in each holes.

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