Page 1 Revision: 9.3 Date: 12/18/18 RV-12 MAINTENANCE MANUAL Aircraft Serial Number: ___________________________...
Page 2 Rev: 9.3 12/18/18 REVISION SUMMARY CHAPTER REVISION DATE COVER PAGE 12/18/18 12/18/18 07/16/16 iv-viii 12/18/18 12/18/18 04/16/10 12/18/18 12/18/18 12/18/18 07/16/16 04/03/14 12/18/18 12/18/18 04/16/10 07/16/16 07/16/16 04/03/14 07/16/16 04/16/10 04/16/10 12/18/18 12/18/18 07/16/16 12/18/18...
Page 3 Van's Aircraft may send the owner/operator supplemental notification bulletins. The owner/operator of an RV-12 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.
Page 4: Table Of Contents
Rev: 7 12/18/18 TABLE OF CONTENTS CHAPTER 1- GENERAL ......................... 1-1 NTRODUCTION Purpose ........................1-1 Summary ........................1-1 Scope .......................... 1-2 Replacement Parts ...................... 1-3 Method ........................1-3 ....................1-4 PPLICABLE HROUGHOUT General Safety ......................1-4 Safety of Flight Reporting Procedure ................1-5 Helpful Terminology ....................
Page 5 Rev: 7 12/18/18 Engine ......................... 3-8 Firewall Forward ......................3-8 Fuselage ........................3-10 Landing Gear ......................3-11 Wing / Center Section/AOA ..................3-12 Rear Spar Doubler ....................3-13 Empennage ....................... 3-14 Angle-Of-Attack System .................... 3-17 Paperwork ......................... 3-17 CHAPTER 4 - STRUCTURAL REPAIRS ................. 4-1 ........................
Page 6 Rev: 7 12/18/18 CHAPTER 10 - UTILITY SYSTEMS ................10-1 ........................10-2 VERVIEW ..........................10-2 ........................10-3 ENTILATION ........................10-4 ERVICE CHAPTER 11 - PROPELLER ..................11-1 ........................11-2 VERVIEW ........................11-2 ERVICE Prop & Hub ....................... 11-3 CHAPTER 12 - FIREWALL FORWARD ................. 12-1 ........................
Page 7 Rev: 7 12/18/18 CHAPTER 19 - GLOSSARY ................... 19-1 CHAPTER 20 - INDEX ....................20-1 NOTE: Pages 1-21 and 1-22 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.
Page 8: O Verview
Rev: 7 12/18/18 TABLE OF ILLUSTRATIONS Figure 1: Tools ........................1-9 Figure 2: Oil Viscosity ...................... 1-13 Figure 3: Lifting and supporting ..................1-17 Figure 4: Remove for inspection ..................3-4 Figure 5: Control Stops ..................... 3-6 Figure 6: Rivet Inspection ....................3-10 Figure 7: Wing Retention Pin Bushing................
Page 9: Chapter 1- General
CHAPTER 1 - GENERAL INTRODUCTION PURPOSE The purpose of this manual is to provide guidance to RV-12 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.
Page 10: Scope
LSA are included in this manual. The general service and maintenance duties that are common to standard aircraft still apply to the RV-12 regardless of the inclusion of those requirements in this manual. All inspection and maintenance and all maintenance log entries must be made in accordance with 14 CFR / FAR’s.
Page 11: Replacement Parts
Rev. 8 REPLACEMENT PARTS The RV-12 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.
Page 12: Applicable Throughout
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-12 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 RV-12.
Page 13: Safety Of Flight Reporting Procedure
RV-12 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.
Page 14: Abbreviations
Rev. 8 BBREVIATIONS A&P* Airframe and Power-plant Kilometers per hour Mechanic Anti-knock index (octane rating) Knots American Petroleum Institute U.S. pound AST* Anti-servo/trim tab Low-Lead AVGAS Aviation Gasoline Light Sport Aircraft Celsius LSA-RM* Light Sport Aircraft – Repairman Maintenance rating Center of Gravity Liter Cylinder Head Temperature...
Page 15: Units
Rev. 8 NITS 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:...
Page 16: Tools And Expendables
Rev. 8 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: T HIS TOOL LIST DOES NOT INCLUDE ALL OF THE TOOLS SUGGESTED FOR THE NSPECTION PROCEDURES TOOLS Combination...
Page 17 Rev. 8 Combination Wrenches Ratchet Screwdrivers Allen Wrenches Sockets Gap Gauge Oil Filter Cutter Heavy Stands Step Ladder Oil Filter Wrench Battery Charger Multi-meter Magnifying Glass Square Air Pressure Gauge Figure 1 1–9...
Page 18 Rev. 8 Razor Knife Flashlight Needle-nose Pliers C-clamp Terminal Crimper Wire Cutter Locking Pliers Blind Riveter Power-drill Dual Vacuum Gauge Hardware Tensile Weight Scale Figure 1 1–10...
Page 19 Rev. 8 ■ CAUTION: R EPLACEMENT PARTS MUST BE OF EQUIVALENT SIZE TYPE AND RATING AS THE ORIGINAL PARTS FROM THE MANUFACTURER EXPENDABLE PARTS PART NUMBER Oil filter Rotax 825 701 Copper crush ring (for drain plug) Rotax 250010 Gas-5 O-ring gasket GASKET GAS-345 Tire U-5:00X5 Tire (any aircraft grade 5:00X5, 4 or 6...
Page 20: Engine
Rev. 8 ENGINE ● NOTE: T HE ENGINE SPECIFICATION INFORMATION IS REFERENCED FROM THE ’ , OM R OTAX SERIES PERATOR S MANUAL SUMMARY Make Rotax 912 ULS Displacement 1352 cc Ignition Ducati Double CDI Carburetor Bing Rated Horsepower 100 Hp @ 5800 RPM DESCRIPTION The LSA covered by this manual will have a Rotax 912ULS power plant.
Page 21: Lubrications And Capacities
Rev. 8 LUBRICATION AND CAPACITIES ENGINE OIL ■ CAUTION: ONLY USE API 'SG' CLASS OR HIGHER ■ CAUTION: DO NOT USE O WITH FRICTION MODIFIER ADDITIVES ■ CAUTION: DO NOT USE O “ ” CONVENTIONAL AIRCRAFT ENGINES ■ CAUTION: DO NOT USE O DESIGNED FOR DIESEL ENGINES Capacity: 3 ltr (3.2 US qts) ♦...
Page 22: Engine Coolant
Rev. 8 ENGINE COOLANT UITABLE OOLANTS OOLANT MIX 50% ethylene glycol concentrate with anticorrosion additives designed for aluminum without sulfates and phosphates,. 50% distilled or de-mineralized water. See the latest version of the Rotax Operators Manual and SI 912-016 for further information on coolant types and limitations.
Page 23: Torque Values
Rev. 8 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 with self-locking nuts the chart values must be modified.
Page 24: General Procedures
Rev. 8 GENERAL PROCEDURES IRE REMOVAL EFER TO ING REMOVAL ANOPY REMOVAL OWL REMOVAL 12-1 EFER TO IL LEVEL CHECK UEL SYSTEM DRAINING 13-1 EFER TO ASCOLATOR AMPLE LIFTING & SUPPORTING THE FUSELAGE ▲ WARNING: U SE STURDY SUPPORT STANDS THAT ARE EACH CAPABLE OF SUPPORTING AT LEAST POUNDS ■...
Page 25: Figure 3: Lifting And Supporting
Rev. 8 IFTING WITH A JACK ■ CAUTION: U SE APPROPRIATE JACK LOCATING FIXTURES TO ENSURE A STABLE JACKING SURFACE ■ CAUTION: I NSTALL 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.
Page 26: Weight And Balance
18. Enter values for Empty Weight, Empty Moment, and Empty Arm into the table on “YOUR AIRPLANE” table within RV-12 Pilot Operating Handbook Section 6. 19. Place the RV-12 Weight & Balance Worksheet in the aircraft as it is part of the required documentation.
Page 27 Rev. 8 RV-12 W & B EIGHT ALANCE ORKSHEET 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...
Page 28 Rev. 8 EIGHT AND ALANCE ECORD 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: ___________________________ As of this date: ___/___/___ the following values represent current Weight and Balance calculations resulting from the installation of the _______________________________.
Page 29: E Quipment L Ist
Rev. 8 INSTALLED EQUIPMENT LIST ITEM WEIGHT MOMENT Lbs. In-lbs. DYNON 56.62 D-180 GARMIN 55.30 GTX 327 GTX 327 TRAY 53.71 GARMIN 53.86 GTX 328 GTX 328 TRAY 53.88 GARMIN 53.76 SL-40 SL-40 TRAY 47.69 GARMIN X95/6 58.08 FLIGHTCOMFC 56.48 ARTEX 96.18 ME-406...
Page 30 Rev. 8 THIS PAGE INTENTIONALLY LEFT BLANK 1-22...
Page 31 Rev. 8 INSTALLED EQUIPMENT LIST ITEM WEIGHT MOMENT Lbs. In-lbs. DYNON 57.90 SV-D1000(T) DYNON (DUAL) 57.90 SV-D1000(T) DYNON 47.12 SV-EMS-220 DYNON 47.66 SV-XPNDR-261 DYNON 54.58 SV-BAT-320 DYNON 141.73 SV-ADAHRS-200 DYNON 43.13 SV-GPS-250 DYNON 43.13 SV-GPS-2020 GARMIN 54.13 GTR 200 ACK 406 96.18 BATTERY 43.56...
Page 32 Rev. 8 INSTALLED EQUIPMENT LIST ITEM WEIGHT MOMENT Lbs. In-lbs. GARMIN GTR225 PS ENGINEERING PM3000-RV TOTAL -------- 1-22 SKYVIEW...
Page 33 Rev. 8 INSTALLED EQUIPMENT LIST ITEM WEIGHT MOMENT Lbs. In-lbs. GARMIN 57.90 GDU 460 GARMIN 57.90 GDU 465 GARMIN 57.57 GMC 305/307 GARMIN 47.12 GEA 24 GARMIN 50.93 GTX 23ES GARMIN 141.73 GMU 22 50.73 IBBS-12V-3AH GARMIN 118.76 GSU 25 GARMIN 43.13 GA 26C...
Page 34 Rev. 8 INSTALLED EQUIPMENT LIST ITEM WEIGHT MOMENT Lbs. In-lbs. GARMIN GTR225 PS ENGINEERING PM3000-RV TOTAL -------- 1-22...
Page 35: Chapter 2- Service Schedule
LSA. At least one of the following qualifications is necessary to perform preventative maintenance on an S-LSA RV-12: The owner or operator provided they are Sport Pilot certified or better. ♦...
Page 36 Rev. 1 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 original KAI for the specific hardware size, location, and configuration.
Page 37: Chapter 3- Inspection
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-12 aircraft they must possess at least one of the following SPECIFIC CERTIFICATION REQUIREMENTS: A person certified as “Repairman (light-sport aircraft)-Maintenance”...
Page 38 Rev. 5 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.
Page 39: Inspection Description
Rev. 5 INSPECTION DESCRIPTION OOLS Inspection Mirror Multi-meter ♦ Clean rags Compression tester ♦ ♦ Straight edge (avoid scratches; tape Torque wrench (in/lbs & ft/lbs) ♦ ♦ along one edge) Tire pressure gauge ♦ Small square Jack ♦ ♦ Screwdrivers: Padded stands ♦...
Page 40: Figure 4: Remove For Inspection
Rev. 5 Figure 4: Remove for inspection *Ref. # Name *Ref. # Name Left Wing Access Hatch Right Wing Seat Floor Cover Forward Skin Cover Plates (5) Upper Forward Fuselage Baggage Floor Cover Skin Top Cowl Baggage Cover Bottom Cowl Baggage Bulkhead Corrugation Spinner Lower Tailcone Fairing...
Page 41: Cockpit
Rev. 5 COCKPIT Tools Magnifying glass Clean rag ♦ ♦ Flashlight Straight edge ♦ ♦ Inspection mirror ♦ • Inspect the aft face of the firewall for corrosion, deformation or cracks, especially around fasteners. • Inspect each occupant harness latching mechanism, the condition of the strap material and stitching.
Page 42: Figure 5: Control Stops
Rev. 5 • Make sure the stabilator contacts its up and down stops before the WD-1210 Control Column contacts its 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.
Page 43: Radio
Rev. 5 RADIO • Check the connections, external condition, and installation of each component; the main unit, the antenna and the jacks. OMMUNICATION • Test the operation of the unit per manufacturer specs. (Refer to the Garmin or Dynon installation manual) NTERCOM •...
Page 44: Engine
Rev. 5 cracks, missing material, and delamination. ● NOTE: P ERFORM THE PROP TRACK TEST WITH THE SPARK PLUGS REMOVED • 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.
Page 45 Rev. 5 • Check the forward side of the firewall especially around components and fasteners, around the battery, oil tank assembly, heat exchangers, cowl attach locations, engine mount, and nose gear. The firewall must not have any open passages into the cockpit.
Page 46: Fuselage
Rev. 5 FUSELAGE Tools Magnifying glass Clean rag ♦ ♦ Flashlight Straight edge ♦ ♦ Inspection mirror ♦ • 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.
Page 47: Landing Gear
Rev. 5 LANDING GEAR ▲WARNING: A LIFTED AIRCRAFT MUST BE SECURELY SUPPORTED BY STATIC STANDS OTHER THAN THE JACKING DEVICE HE AIRCRAFT MAY NOT MOVE FROM ATTEMPT TO SHAKE HORIZONTALLY OR VERTICALLY ■CAUTION: A LWAYS USE PADDED STANDS AND ALWAYS DISTRIBUTE THE LOAD ALONG A RIVET PATTERN WITH SEVERAL INTERSECTING RIVET PATTERNS ●NOTE: R –...
Page 48: Wing / Center Section/Aoa
Rev. 5 • Use a straight edge to check that the unloaded gear-leg is straight, between the factory bends. • Inspect the condition of fasteners and cotter pins, and the condition of attach locations at the nose fork pivot point and the three wheel axles. •...
Page 49: Rear Spar Doubler
Rev. 5 • Check fuselage pin latching mechanisms for security and proper operation. Test warning circuit by moving each latch independently and verifying warning light. • 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.
Page 50: Empennage
Rev. 5 • If your aircraft has ES-00076 & ES- 00077 Electrical Connectors (See KAI 31B-08 and 31B-18) and the measurement is less than 0.050 no repair is required. • If your aircraft has tab style VA-262 electrical connectors in UHMW (See KAI 31-02) and the measurement is less than 0.010 no repair is required.
Page 51: Figure 8: Rudder Stop
Rev. 5 • Check the fiberglass fairing for condition and security. • Check the rudder control horn for coating damage. Inspect for cracks, missing fasteners and deformation. • Check the spar bottom rib surrounding the rudder horn for cracks or deformation. •...
Page 52: Stabilator
Rev. 5 TABILATOR • Check the main skin for damage or deformation. • Check the main skin fasteners by sighting along each rivet pattern for any inconsistent rivet profile among similar properly installed rivets. • Inspect the Anti-Servo Tab hinges, fasteners, and safety wire for wear and security. •...
Page 53: Angle-Of-Attack System
Rev. 5 ANGLE-OF-ATTACK SYSTEM TEST Tools Syringes - two req'd (35cc or similar) Modeling clay ♦ ♦ Vacuum hose (or soft plastic tubing) ♦ NOTE: T SYSTEM PLUMBING MUST PASS THIS LEAK TEST DURING EVERY INSPECTION AND EVERY TIME THE WINGS ARE REMOVED AND INSTALLED AOA, S HEN PERFORMING ANY TATIC...
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Page 55: Chapter 4 - Structural Repairs
Rev. 3 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.
Page 56: Minimum Certification
KAI Chapter 5; Construction Materials, Processes & Useful Information. • 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. •...
Page 57: Chapter 5 - Structures
Rev. 6 CHAPTER 5 - STRUCTURES ..........5-2 Installation ..........5-14 VERVIEW Main wheel and tire assembly removal ..5-15 ........... 5-2 USELAGE Installation ..........5-15 Components ........5-3 Nose wheel and tire assembly removal ..5-16 ......5-4 Installation ..........5-16 ING AND LAPERON Main inner tube replacement .......
Page 58: Overview
Rev. 6 OVERVIEW The RV-12 airframe uses blind (pop style) rivets as the primary fastener. The wings are removable without the need of tools. Screws, bolts and solid rivets are used where necessary. • NOTE: P RIOR TO PERFORMING STRUCTURAL REPAIRS READ...
Page 59: Figure 9: Fuselage
Rev. 6 Figure 9: Fuselage COMPONENTS Quantity Part or Assembly Name Part Number or Reference Canopy and Frame C-1201 & WD-1219 Fuselage Refer to KAI Fuselage Pin WD-1217 Wing Retention Pin Bushing W-1206U Latch Block C-1205 Occupant Harness System See shaded items below & Refer to KAI Shoulder Harness Lap Belt Crotch Strap...
Page 60: Wing And Flaperon
Rev. 6 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.
Page 61 Rev. 6 COMPONENTS Quantity Part or Assembly Name Part Number or Reference Left Wing See shaded items below & Refer to KAI Wing Retention Pin Bushing W-1206U Stub Spar W-1208B-L / W-1208C-L Rear Spar W-1207A-L / W-1207B Stall Warning See 5-5 Right Wing See shaded items below &...
Page 62: Empennage
Rev. 6 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 and rudder. 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.
Page 63 Rev. 6 COMPONENTS Quantity Part or Assembly Name Part Number or Reference Vertical Stabilizer See shaded items below & Refer to KAI Lower Hinge VS-1210 / VS-1211A / COM-3-5 Upper Hinge VS-1210 / VS-1211B / COM-3-5 Fwd Skin VS-1204 Rudder See shaded items below &...
Page 64: Landing Gear
Rev. 6 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, spacer, and wheel and tire assembly to the nose fork.
Page 65 Rev. 6 COMPONENTS Quantity Part or Assembly Name Part Number or Reference Left Main Gear U-1220-L Right Main Gear U-1220-R Outbd Main Gear Attach Brkt U-1202 Outbd Doubler Plate U-1202C Outbd Wear Plate U-1202D Inbd Main Gear Attach Brkt U-1203 Inbd Wear Plate U-1203B Doubler Plate...
Page 66: Figure 13: Nose Wheel And Gear Leg Fairings
Rev. 6 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.
Page 67: Figure 14: Main Wheel Fairings
Rev. 6 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. Figure 14: Main Wheel Fairings OPTIONAL COMPONENTS Quantity...
Page 68: Service
Rev. 6 SERVICE SUPPLIES OOLS XPENDABLE Needle nose pliers Cotter pins ♦ ♦ Sockets: Safety wire ♦ ♦  3/8 Wheel bearing grease ♦  5/16 Spray lubricant ♦  7/16 Inner tube ♦  1/2 Hydraulic fluid ♦  9/16 Loctite ♦...
Page 69 Rev. 6 GENERAL ING REMOVAL No tools or certification required. ■ CAUTION: B E PREPARED WITH A HELPER OR SUPPORT STAND TO HANDLE THE WEIGHT AND AWKWARDNESS OF THE OBJECT TO BE REMOVED ■ CAUTION: A LWAYS SUPPORT THE FLAPERON DURING WING REMOVAL AND STORAGE 1.
Page 70 Rev. 6 ENTER ECTION 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. PARS 3. Tap out the bushing from the non-flanged end of the bushing. 4.
Page 71 Rev. 6 AIN WHEEL AND TIRE ASSEMBLY REMOVAL Tools Needle nose pliers 1 1/2, 7/16 socket Expendable Cotter pins Safety wire Replaceable None Service Rating Preventative Owner and SPC, LSA-RM, or A&P Minimum Certification Additional References Matco user manual 1. Lift and support the aircraft. (1-16) 2.
Page 72 Rev. 6 OSE WHEEL AND TIRE ASSEMBLY REMOVAL Tools 9/16 socket 9/16 combo wrench Expendable None Replaceable None Service Rating Preventative Minimum Certification Owner and SPC, LSA-RM, or A&P Additional References Matco user manual 1. Lift and support the aircraft. (1-16) 2.
Page 73 Rev. 6 OSE INNER TUBE REPLACEMENT Tools 3/16 Allen Expendable Inner tube Replaceable Nose wheel assembly Tire Service Rating Preventative Minimum Certification Owner and SPC, LSA-RM, or A&P Additional References Matco user manual Lift and support the aircraft. (1-16) Remove the nose wheel and tire assembly. (5-16) Deflate the inner tube.
Page 74: Figure 15: Flaperon Hinge
Rev. 6 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. 7.
Page 75 Rev. 6 ■ CAUTION: U PPER 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 tailcone fairing. TABILATOR HINGE REPLACEMENT Tools 1/4 drive socket slightly less than 5/8in in diameter.
Page 76: Figure 16: Extracting The Dw4K2X Bearing
Rev. 6 3. Remove the Lock Clips from one of the cable tensioners. 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.
Page 77 Rev. 6 AIN GEAR REMOVAL Tools 7/16, 1/2, 9/16 socket 7/16, 1/2, 9/16 combo wrench Expendable Hydraulic fluid Replaceable Left Main Gear Right Main Gear Outbd Main Gear Attach Brkt Outbd Wear Plate Inbd Main Gear Attach Brkt Inbd Wear Plate Service Rating Line Minimum Certification...
Page 78 Rev. 6 ▲ WARNING: D O NOT REMOVE THE UPPER VIBRATION ISOLATOR BOLTS 3. Remove the lower engine vibration-isolator bolts (2). 4. Remove the nose gear-leg hardware from the fuselage; bolts (13) and washers (13). ● NOTE: T HE ENGINE CAN BE LIFTED BY HAND AT THE GEARBOX 5.
Page 79 Rev. 6 ANOPY LATCH BLOCK REPLACEMENT Tools #2 Phillips screwdriver Expendable None Replaceable Latch Block Service Rating Line Minimum Certification LSA-RM, or A&P Additional References 1. Remove the latch block attach screws (2) and the latch block. 2. Install the new latch block and attach hardware. TEP REPLACEMENT Tools 7/16 socket...
Page 80: Figure 16.1: Rear Spar Doubler Replacement
Rev. 6 5. 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, remove the wing, un- cleco the doubler and sand the contour of the curve 0.010”...
Page 81 Rev. 6 SERVICE SCHEDULE PROCEDURES ING ATTACH LOCATION LUBRICATION WINGS REMOVED Tools None Expendable Wheel bearing grease Anti-seize compound Replaceable Fuselage Pin Service Rating Preventative Owner and SPC, LSA-RM, or A&P Minimum Certification Additional References USELAGE PINS 1. Wipe clean, the fuselage pins (2). 2.
Page 82 Rev. 6 LAPERON BEARINGS LUBRICATION Tools None Expendable Spray lubricant Replaceable None Service Rating Preventative Minimum Certification Owner and SPC, LSA-RM, or A&P Additional References Flaperon hinge replacement (5-17) 1. Wipe away any dirt accumulation from each of the flaperon bearings (3). 2.
Page 83 Rev. 6 4. Split the wheel and tire assembly by removing the bolts (3), washers (6), and nuts (3). 5. Press the wheel bearing out from the inside of each wheel half. 6. Press a new wheel-bearing into each wheel half. 7.
Page 84 Rev. 6 OSE FORK PIVOT TENSION AND LUBRICATION Tools Needle nose pliers 1 1/2 socket Tensile weight scale Expendable Waterproof wheel bearing grease Replaceable Nose fork bushings Service Rating Line Minimum Certification LSA-RM, or A&P Additional References 1. Lift and support the aircraft. (1-16) 2.
Page 85 Rev. 6 TIRE ASSEM. BALANCING PROCEDURE ● NOTE:I T IS NOT A MAINTENANCE REQUIREMENT THAT THE OSE OR RV-12 HEEL SSEMBLIES ON THE BE BALANCED BECAUSE OF THE RELATIVELY LOW TAKEOFF AND LANDING SPEED HOULD A VIBRATION BE DETECTED THAT IS SUSPECTED TO BE CAUSED BY A WHEEL...
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Page 87: Chapter 6 - Flight Controls
Rev. 4 CHAPTER 6 - FLIGHT CONTROLS ........................6-2 VERVIEW Components ........................ 6-2 .......................... 6-3 ERVICE Supplies ........................6-3 Tools ..................................6-3 Expendable ................................6-3 Replaceable ................................6-3 General ........................6-3 Stabilator pulley replacement and cable tension adjustment ................. 6-3 Control cable replacement .............................
Page 88: Overview
Refer to the KAI to identify the individual parts and part #’s of the control system. • NOTE: This maintenance manual is intended to be used in conjunction with the RV-12 Kit Assembly Instructions (KAI) when completing maintenance or repair processes. COMPONENTS...
Page 89: Service
Rev. 4 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 OOLS XPENDABLE Needle nose pliers Cotter pins ♦...
Page 90: Figure 17: Locking Clip Removal
Rev. 4 1. Remove the seat ramp cover and cover plate (only the aft two). (3-4) 2. Remove the stabilator control cable barrel lock clips from one barrel as shown in Figure 17. Figure 17: Locking clip removal 3. Loosen the tension of the stabilator cables by...
Page 91 Rev. 4 8. Install the F-1227 Seat Ramp Cover (refer to KAI). If the four screw holes for the F-1233 Control Column Mount Brackets (refer to KAI) do not align with the cover, a light upward pull on the stick will correct the misalignment until the screws are inserted and tightened.
Page 92: Control Cable Replacement
Rev. 4 ONTROL CABLE REPLACEMENT ■ C AUTION HE CONTROL SURFACE WILL SWING FREELY WHEN THE CONTROL CABLES ARE REMOVED ● NOTE: A LWAYS REPLACE CONTROL CABLES AS A SET Tools 3/8, 7/16 socket 3/8, 7/16 combo wrench Needle nose pliers String Cable tension meter Spring clamps (3)
Page 93: Rod End Replacement
Rev. 4 ● NOTE: T HE SEAT RAMP COVER MUST BE INSTALLED PRIOR TO ADJUSTING THE CABLE TENSION 7. Installation procedure is reverse of the removal procedure. 8. Adjust cable tension as described earlier in this chapter. OD END REPLACEMENT Tools 3/8, 7/16 socket 3/8, 7/16 combo wrench...
Page 94: Bellcrank Bearing Replacement
Rev. 4 ELLCRANK BEARING REPLACEMENT Tools 3/8, 7/16, 3/4, 11 mm socket 3/8, 7/16 combo wrench 2 1/2x3/16 bolt, washer, and Expendable None Replaceable Bearing DW4K2X Service Rating Line Minimum Certification LSA-RM, or A&P Additional References 1. Remove the seat ramp cover and seat floor cover. (3-4) 2.
Page 95: Installation
Rev. 4 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. NSTALLATION 1. Installation procedure is reverse of the removal procedure. SERVICE SCHEDULE PROCEDURES ONTROL SYSTEM ROD END LUBRICATION Tools #2 Phillips 3/8, 7/16 sockets...
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Page 97: Chapter 7 - Brake System
Rev. 2 CHAPTER 7 - BRAKE SYSTEM ........................7-2 VERVIEW Components ........................ 7-2 .......................... 7-2 ERVICE Supplies ........................7-3 Tools ..................................7-3 Expendable ................................7-3 Replaceable ................................7-3 General ........................7-3 Master cylinder removal............................7-3 Removal ................................7-3 Disconnection ..............................7-4 Installation ................................
Page 98: Overview
Since the brakes on the RV-12 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...
Page 99: Supplies
Rev. 2 SUPPLIES ■ CAUTION: U ONLY MIL-H-5606A ! DO NOT MIL SPEC HYDRAULIC FLUID AUTOMOTIVE BRAKE FLUID AMAGE TO RING SEALS MAY RESULT OOLS XPENDABLE Socket: Hydraulic fluid ♦ ♦  3/8 Wheel bearing grease ♦  7/16 Cotter pins ♦...
Page 100: Figure 19: Torque Tube Lubrication
Rev. 2 ISCONNECTION 1. Drain the hydraulic fluid. (7-5) 2. Make note of the hose connections. 3. Disconnect brake lines from master cylinder. NSTALLATION 1. Installation procedure is reverse of the removal procedure. 2. Bleed the brake system. (7-5) SERVICE SCHEDULE PROCEDURES RAKE PEDAL TORQUE TUBE LUBRICATION Tools 7/16 socket...
Page 101: Hydraulic Fluid Drain, Flush, And Replace
Rev. 2 4. Remove the brake pedal from the pivot tube. 5. Remove the pivot tube from the rudder pedal. 6. Clean the pivot tube then apply lubricant to the exterior of the tube. 7. Installation procedure is reverse of the removal procedure. YDRAULIC FLUID DRAIN FLUSH AND REPLACE...
Page 102: Brake Lining Replacement
Rev. 2 RAKE LINING REPLACEMENT ● NOTE: I T IS RECOMMENDED TO REPLACE OF THE BRAKE LININGS ON BOTH SIDES EVEN IF ONLY ONE LINING REQUIRES REPLACEMENT Tools 7/16 socket Expendable Brake linings Safety wire Replaceable Brake disc Service Rating Line Minimum Certification LSA-RM or A&P...
Page 103: Chapter 8 - Electrical System
Rev. 5 CHAPTER 8 - ELECTRICAL SYSTEM ........................8-2 VERVIEW Components ........................ 8-2 Optional Lighting ......................8-3 Optional Components ....................8-3 .......................... 8-4 ERVICE Supplies ........................8-4 Tools ..................................8-4 Expendable ................................8-4 Replaceable ................................8-4 General ........................8-5 Battery removal ..............................8-5 Installation ................................
Page 104: Overview
ERIOUS RISK OF ELECTRIC SHOCK REMAINS AFTER THE POWER SUPPLY IS REMOVED The RV-12 electrical system is a 12 VDC, negative ground system. A 12 VDC sealed dry cell battery mounts on the forward side of the firewall. The generator operates only while the engine is running.
Page 105: Figure 20: Optional Wing Tip Lighting
Rev. 5 OPTIONAL LIGHTING The lighting components include the wing tip strobe light, extension, landing light rib, landing light, lens backing strip, landing light lens, cooling shroud and red eyeball cockpit light. See Figure 20. The wing tip light mounts in the extension which attaches to the wing tip.
Page 106: Service
Rev. 5 SERVICE ▲WARNING: A LWAYS HAVE AN APPROPRIATE FIRE EXTINGUISHER READILY AVAILABLE ▲WARNING: B EFORE PERFORMING ANY MAINTENANCE OR REPAIRS TURN THE MASTER SWITCH AND DISCONNECT THE NEGATIVE BATTERY CABLE FROM THE BATTERY ■ C AUTION EPLACEMENT COMPONENTS WIRE TERMINALS AND FUSES MUST BE OF THE SAME TYPE AND RATING AS THE ORIGINAL PARTS...
Page 107: General
Rev. 5 GENERAL ATTERY REMOVAL ▲ WARNING: N EUTRALIZE BATTERY CORROSION WITH WATER BAKING SODA MIX Tools 4 mm allen wrench, 3/8 socket Expendable None Replaceable Battery Service Rating Preventative Minimum Certification Owner and SPC, LSA-RM or A&P Additional References Odyssey owner manual 1.
Page 108: Figure 21: Fuse Panel
Rev. 5 USE REPLACEMENT ■ CAUTION: B LOWN FUSES MUST BE REPLACED ONLY WITH FUSES OF THE SAME TYPE AND RATING AS SPECIFIED BY THE MANUFACTURER ■ CAUTION: T ‘ ’ HE MASTER SWITCH MUST BE IN THE POSITION BEFORE REPLACING ANY FUSE ●...
Page 109: Pitch-Trim Servo Replacement
Rev. 5 ITCH TRIM SERVO REPLACEMENT Tools 3/8, 7/16 socket 3/16 combo wrench #2 Phillips screwdriver Wire cutter Terminal crimping tool Needle nose pliers Expendable Wire terminals Replaceable Pitch-Trim servo Service Rating Line Minimum Certification LSA-RM, or A&P Additional References 1.
Page 110: Figure 22: Trim/Servo Assembly Removal
Rev. 5 Figure 22: Trim/Servo assembly removal 7. Remove the pitch-trim servo attach screws (6), washers (6), nuts (6), and doublers (2) as shown in Figure 23. 8. Unscrew the pitch-trim servo from the pushrod assembly. Remove the jam nut from the pitch-trim servo shaft.
Page 111: Electrical Component Replacement
Rev. 5 2. 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.
Page 112: Figure 24: Stall Warning Ground
Rev. 5 type. 8. Re-attach applicable electrical and mechanical connections. 9. Reconnect the negative (-) battery cable. AV C ONTROL BOARD REPLACEMENT Tools #2 Phillips screwdriver small flat blade screwdriver Expendable None Replaceable AV Control Board Service Rating Line Minimum Certification LSA-RM,A&P or Approved Owner Additional References...
Page 113: Wire Repair
Rev. 5 IRE REPAIR Tools Wire cutter Wire terminal crimper Multi-meter Expendable Wire terminals Replaceable Wire Service Rating Line Minimum Certification LSA-RM, or A&P Additional References ASTM F39 F2639 ■ CAUTION: T HE REPLACEMENT WIRE SIZE AND TYPE MUST BE EQUAL TO THE ORIGINAL 1.
Page 114 Rev. 5 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.
Page 115: Figure 25: Snap Bushing
Rev. 5 NAP BUSHING REPLACEMENT Tools Razor knife Expendable None Replaceable Snap bushing Service Rating Line Minimum Certification LSA-RM, or A&P Additional References 1. Extract the failed snap bushing by compressing the two locking tabs and pushing it out of the mounting hole. 2.
Page 116: Service Schedule Procedures
Rev. 5 SERVICE SCHEDULE PROCEDURES ATTERY TERMINAL CLEANING ▲ WARNING: N EUTRALIZE BATTERY CORROSION WITH WATER BAKING SODA MIX Tools Scouring pad Expendable Baking soda/water Replaceable None Service Rating Preventative Minimum Certification Owner and SPC, LSA-RM, or A&P Additional References Odyssey owners manual 1.
Page 117: Chapter 9 - Instruments & Avionics
Rev. 6 CHAPTER 9 - INSTRUMENTS & AVIONICS ........................9-2 VERVIEW Components ........................... 9-2 Optional Components ......................9-3 & S ......................... 9-3 ITOT TATIC Components ........................... 9-3 .......................... 9-4 ERVICE Supplies ........................9-4 Tools ........................... 9-4 Expendable ......................... 9-4 Replaceable ........................
Page 118: Overview
A flexible plastic tube continues aft from the adapter block to the air data computer. • NOTE: This maintenance manual is intended to be used in conjunction with the RV-12 Kit Assembly Instructions (KAI) when completing maintenance or repair processes. COMPONENTS Quantity...
Page 119: Optional Components
Rev. 6 OPTIONAL COMPONENTS Autopilot Servo See Dynon or Garmin Manual Dynon AP-74 Autopilot Interface Module IF DYNON AP AP74V-12 Dynon Manual SV-AP-PANEL See Dynon Manual SV-KNOB-PANEL See Dynon Manual Garmin GMC 305 Autopilot Controller See Garmin Manual Landing light See Aero LED Manual Navigation / Strobe light See Aero LED Manual...
Page 120: Service
Rev. 6 COMPONENTS Quantity Part or Assembly Name Part Number or Reference Static Source Rivet SD-42-BSLF Plastic Tee 125 X 125 X 125 TEE Pitot Block FF-1201, UHMW Pitot Tube FF-1202, AT6-058X5/16 SERVICE ▲WARNING: A LWAYS HAVE AN APPROPRIATE FIRE EXTINGUISHER READILY AVAILABLE ▲WARNING: B EFORE PERFORMING ANY MAINTENANCE OR REPAIRS TURN THE MASTER...
Page 121: General
2. Remove the failing component. NSTALLATION 1. Install a new component of equivalent properties and secure with plastic tie wraps. 2. Complete the pitot /static check as outlined in the RV-12 production acceptance test document. IGHT REPLACEMENT ▲WARNING: B EFORE PERFORMING ANY MAINTENANCE OR REPAIRS TURN THE MASTER...
Page 122: Service Schedule Procedures
Rev. 6 EMOVAL 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. NSTALLATION 1.
Page 123: Chapter 10 - Utility Systems
Rev. 1 CHAPTER 10 - UTILITY SYSTEMS ........................10-2 VERVIEW ..........................10-2 Components ......................10-3 ........................10-3 ENTILATION Components ......................10-4 ........................10-4 ERVICE Supplies ........................10-4 Tools ..................................10-4 Replaceable ................................. 10-4 Expendable ................................10-4 General ........................10-5 Vent door repair ..............................10-5 Service Schedule Procedures ...................
Page 124: Overview
• NOTE: This maintenance manual is intended to be used in conjunction with the RV-12 Kit Assembly Instructions (KAI) when completing maintenance or repair processes. HEAT Air that passes through the engine coolant heat exchanger is heated.
Page 125: Components
Rev. 1 COMPONENTS Quantity Part or Assembly Name Part Number or Reference Cooler box FF-1204 Cooler box door FF-1205 Cooler box bracket FF-1205BC Cooler box hinge FF-1206 Push / Pull Cable CT A-740 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.
Page 126: Components
Rev. 1 COMPONENTS Quantity Part or Assembly Name Part Number or Reference Vent brackets F-1086 Vent doubler F-1096 Vent door sub-assembly See shaded items below Vent slide F-1087 Vent door doubler F-1092 Vent door F-1093 SERVICE The heating system does not require regular maintenance. If the push / pull cable operation is not smooth at the time of the annual condition inspection, lubricate the moving parts.
Page 127: General
Rev. 1 GENERAL ENT DOOR REPAIR Tools #30 drill bit Blind rivet tool 1/4 combo wrench #2 Phillips screwdriver Expendable LP4-3 rivets (4) Screw Plastic washers (2) Metal washer Replaceable Vent door sub-assembly Vent brackets (2) Service Rating Line Minimum Certification LSA-RM or A&P Additional References 1.
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Page 129: Chapter 11 - Propeller
Rev. 4 CHAPTER 11 - PROPELLER ........................11-2 VERVIEW Components ......................11-2 ........................11-2 ERVICE Supplies ........................11-2 Tools ..................................11-2 Expendable ................................11-2 Replaceable ................................. 11-2 Spinner and Pitot Tube 11-3 ..........................Prop & Hub ........................ 11-3 11-1...
Page 130: O Verview
Rev.4 OVERVIEW The RV-12 has a ground adjustable Sensenich propeller. For instructions to adjust the propeller pitch, refer to the 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.
Page 131: Prop & Hub
Rev.4 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.
Page 132 Rev.4 • 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. • If the propeller shows any of the following signs of damage it must either be repaired (if possible) or retired from service: Cracks in the metal hub or bolts ...
Page 133: Chapter 12 - Firewall Forward
Rev.5 CHAPTER 12 - FIREWALL FORWARD ..................................12-2 VERVIEW Components ..................................12-2 Engine ..................................... 12-3 Rotax 912ULS ..............................12-3 Spark Plugs ..............................12-3 Ignition ................................12-3 ..................................12-3 ERVICE Supplies ................................... 12-4 Tools ..................................12-4 Expendable ................................12-4 Replaceable ................................. 12-4 General ...................................
Page 134: Overview
Air duct and engine cooling shrouds of similar construction provide cooling to the cylinders and heat exchangers. • NOTE: This maintenance manual is intended to be used in conjunction with the RV-12 Kit Assembly Instructions (KAI) when completing maintenance or repair processes. COMPONENTS Quantity...
Page 135: Figure 26: Rotax 912Uls
Rev.5 ENGINE Figure 26: 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.
Page 136: Supplies
Rev.5 SUPPLIES OOLS XPENDABLE Socket: Spray lubricant ♦ ♦  3/8 Engine coolant ♦  5/16 Engine oil ♦  9/16 Dry lubricant ♦  16 mm (spark plug type) Oil filter ♦ Combination wrench: Safety wire ♦ ♦  3/8 Cotter pins ♦...
Page 137: Engine Oil Level Check
Rev.5 PARK PLUG REPLACEMENT OR RE INSTALLATION Tools 16mm socket Spark plug gap tool Expendable Heat conduction compound Replaceable Hinge pins Spark Plugs - if serviceable Service Rating Preventative Minimum Certification LSA-RM with Rotax Service certification or A&P with Rotax Service Certification.
Page 138 Rev.5 ■ CAUTION: F ‘M .’ OR LONG FLIGHTS REPLENISH OIL TO THE MARK ON THE DIPSTICK ● NOTE: T ‘M .’ ‘M .’ HE QUANTITY DIFFERENCE BETWEEN MARKS ON OIL 0.45 (0.5 DIPSTICK IS QUART 3. Oil level must be between the ‘Max’ and ‘Min’ marks on the dipstick. NGINE COOLANT LEVEL CHECK ▲...
Page 139 Rev.5 ARBURETOR YNCHRONIZATION Tools 1 - Vacuum gauge set 1 - .050 Allen wrench 2 - 3/8 in. combination wrench 2 - 10 mm combination wrench 1 - medium flat blade screwdriver 1 - #2 Phillips screwdriver Expendable None Replaceable None Service Rating Line...
Page 140: Figure 27: Carburetor Overview
Rev.5 Figure 27: Carburetor Overview (Right Carburetor Shown) ● NOTE: F THROUGH REFER TO IGURES 1. Remove the throttle cable locking hardware from the throttle arm. 2. Release the full throttle return spring from its attachment on the throttle arm. 3.
Page 141: Figure 28: Mixture Screw
Rev.5 1.5 turns counter-clockwise. Note this step cannot be done without removing the carburetor from the manifold. With a new engine initially assume it is properly set at the factory. 8. Hook-up the full throttle return spring, previously disconnected, back to its original position on the throttle arm.
Page 142: Figure 29: Throttle Handle Idle Position
Rev.5 OOKING THE HROTTLE ABLE EAD TO THE HROTTLE 9. Pull the throttle handle away from the instrument panel the distance prescribed in Figure 29, then tighten the friction adjustment. This is the idle position. Figure 29: Throttle Handle Idle Position 10.
Page 143: Figure 30: Vacuum Gauge
Rev.5 Figure 30: Vacuum Gauge Hookup 13. Secure the aircraft to the ground using chocks, ropes etc. ▲ WARNING: S ECURE AND OBSERVE THE PROPELLER ZONE DURING ENGINE OPERATION 14. Start the engine and warm it up until normal operating temperatures are achieved.
Page 144: Off Idle Setting
Rev.5 ETTING 15. After warming the oil temp to the minimum required for takeoff power application, run the engine to full throttle and verify the engine is developing proper power with an indication of at least 4700 RPM. 16. Verify that both vacuum gauge readings are the same when the throttle is slowly moved between near idle and full power.
Page 145 Rev.5 ● NOTE: W HEN 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 HEAVY PULL ON THE THROTTLE CONTROL WILL FLEX THE THROTTLE ARMS AND GIVE AN INACCURATE IDLE SPEED ●...
Page 146: Verify Functionality Of Throttle Return Spring
This may take up to 15 seconds. If the throttle is not pulled to full, the return springs and/or throttle cable need to be replaced before further flight. Consult the RV-12 KAI Section 50. 12-14...
Page 147: Throttle Spring Replacement
Rev.5 HROTTLE PRING REPLACEMENT Tools Small Screw Driver Expendable None Replaceable None Service Rating Preventative Minimum Certification Owner and SPC, LSA-RM or A&P Additional References KAI and ROTAX Line Maintenance Manual 1. Release the friction on the cockpit throttle control and move it to the full open position.
Page 148: Service Schedule Procedures
Rev.5 SERVICE SCHEDULE PROCEDURES OWL HINGE PIN LUBRICATION Tools #2 Phillips screwdriver Expendable Dry lubricant Replaceable None Service Rating Preventative Owner and SPC, LSA-RM or A&P Minimum Certification Additional References 1. With the cowl hinge pins removed wipe each hinge pin clean. 2.
Page 149: Cooling Hose Replacement
Rev.5 OOLING EPLACEMENT ▲ WARNING: B EFORE PERFORMING ANY INSPECTION OR SERVICE ALLOW THE ENGINE COMPONENTS TO COOL Tools 3/8 open end wrench, screwdriver, wire cutters Expendable Plastic tie-wrap 8in Replaceable FF-1208A, FF-1208B, FF-1220 Service Rating Preventative Owner and SPC, LSA-RM or A&P Minimum Certification Additional References EMOVAL...
Page 150 Rev.5 YLINDER PISTON AND VALVE ASSEMBLY REMOVAL Tools 5 mm Allen wrench, 12,13 mm socket, wire cutters, pliers, #2 Phillips & straight slot screwdrivers, and others for engine disassembly Expendable Tie wraps, engine coolant Replaceable Coolant Hoses - reuse if serviceable, coolant Service Rating Heavy Minimum Certification...
Page 151: Engine Replacement
Rev.5 NGINE REPLACEMENT Tools Torque wrench, many common tools as req'd. Expendable Loctite 221, coolant, engine oil Replaceable 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 EMOVAL 1.
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Page 153: Chapter 13 - Fuel System
Rev.5 CHAPTER 13 - FUEL SYSTEM ........................13-2 VERVIEW Components ......................13-2 Fuel System Schematic ..................... 13-3 ........................13-3 ERVICE Supplies ........................13-4 Tools ..................................13-4 Expendable ................................13-4 Replaceable ................................. 13-4 General ........................13-4 Draining the fuel system ............................13-4 Fuel tank removal ..............................
Page 154: O Verview
The gascolator and fine fuel screen requires inspection and cleaning at regular intervals (at least annually). • NOTE: This maintenance manual is intended to be used in conjunction with the RV-12 Kit Assembly Instructions (KAI) when completing maintenance or repair processes. COMPONENTS Quantity...
Page 155: Fuel System Schematic
Rev.5 FUEL SYSTEM SCHEMATIC SERVICE ▲WARNING: A LWAYS HAVE AN APPROPRIATE FIRE EXTINGUISHER READILY AVAILABLE ▲WARNING: B EFORE PERFORMING ANY MAINTENANCE OR REPAIRS TURN THE MASTER SWITCH AND DISCONNECT THE NEGATIVE BATTERY CABLE FROM THE BATTERY ■ C AUTION EPLACEMENT FUEL SYSTEM COMPONENTS MUST BE EQUIVALENT TO THE ORIGINAL PARTS ●...
Page 156: Supplies
Rev.5 SUPPLIES OOLS XPENDABLE Sockets: Safety wire ♦ ♦  1/4  3/8 EPLACEABLE  5/16  7/16 Gas-5 Screen ♦ Combination wrench: Gas-5 O-ring gasket ♦ ♦  3/8  7/16  1/2  11/16  3/4  9/16 Screwdriver ♦...
Page 157: Fuel Tank Removal
Rev.5 FIRST SIPHONING OUT AS MUCH AS POSSIBLE SMALL WEIGHT SECURELY ATTACHED TO THE END OF A FLEXIBLE SIPHON HOSE WORKS WELL FOR REACHING THE TANK S BOTTOM FORWARD END 1. Put the fuel valve in the ‘OFF’ position. 2. Remove the engine cowling. (12-4) 3.
Page 158: Fuel System Component Removal
Rev.5 #2 Phillips screwdriver 3/16 Standard screwdriver Expendable None Replaceable None Service Rating Line Minimum Certification LSA-RM or A&P Additional References 1. Drain the fuel system. (13-4) 2. Remove the two aft access covers from the fuselage bottom skin. (3-4) 3.
Page 159: Service Schedule Procedures
Rev.5 2. Label, 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. NSTALLATION 1. Installation procedure is reverse of the removal procedure. SERVICE SCHEDULE PROCEDURES ▲W ARNING...
Page 160: Fuel Strainer Removal
Rev.5 TRAINER EMOVAL Tools 3/4 combo wrench or deep socket Expendable Thread sealant paste Replaceable None Service Rating Line Minimum Certification LSA-RM or A&P Additional References T IS NOT NECESSARY TO REMOVE THE FUEL TANK IN ORDER TO REMOVE THE FUEL STRAINER 1.
Page 161: Figure 31: Fuel Pressure Hose Flush
Rev.5 Figure 31: Fuel Pressure Hose Flush RESSURE LUSH (* Left Side of Fuel Return Assembly) Tools 2X 9/16 combination wrenches Expendable Fuel, rags, temporary fuel container Replaceable Service Rating Preventative Minimum Certification LSA-RM with Rotax Service certification or A&P with Rotax Service certification Additional References Removal...
Page 162: Fuel Drain Hose Replacement
Rev.5 RAIN EPLACEMENT Tools 1/4 socket or Phillips screwdriver Expendable Tie wraps (2) Replaceable Fuel interconnect and drain hoses Service Rating Preventative Minimum Certification LSA-RM with Rotax Service certification or A&P with Rotax Service certification Additional References Removal 1. Cut the tie wraps attaching the drain hose to the gascolator-to-fuel-pump hose.
Page 163: Chapter 14 - Exhaust System
Rev.2 CHAPTER 14 - EXHAUST SYSTEM ........................14-2 VERVIEW Components ......................14-2 ........................14-2 ERVICE Supplies ........................14-2 Tools ..................................14-2 Expendable ................................14-2 Replaceable ................................. 14-2 General ........................14-3 Exhaust system removal............................14-3 Installation ................................ 14-3 Service Schedule Procedures ................... 14-4 Ball joint lubrication ..............................
Page 164: Tools
The purpose of the muffler is to reduce engine noise. • NOTE: T HIS MAINTENANCE MANUAL IS INTENDED TO BE USED IN CONJUNCTION WITH THE RV-12 K (KAI) SSEMBLY NSTRUCTIONS WHEN COMPLETING MAINTENANCE OR REPAIR...
Page 165: General
Rev.2 GENERAL XHAUST SYSTEM REMOVAL ▲ WARNING: A LLOW THE EXHAUST COMPONENTS TO COOL BEFORE PERFORMING INSPECTION OR SERVICE Tools 13 mm socket Locking pliers Expendable Anti-seize compound, high temp Replaceable Joint spring Service Rating Line Minimum Certification LSA-RM or A&P Additional References 1.
Page 166: Service Schedule Procedures
Rev.2 SERVICE SCHEDULE PROCEDURES ALL JOINT LUBRICATION ▲ WARNING: A LLOW THE EXHAUST COMPONENTS TO COOL BEFORE PERFORMING INSPECTION OR SERVICE Required tools Locking pliers Required expendables Anti-seize compound Replaceable None Service rating Line Minimum Certification LSA-RM or A&P Additional Reference 1.
Page 167: Chapter 15 - Painting And Coatings
Rev.1 CHAPTER 15 - PAINTING AND COATINGS ........................15-2 VERVIEW ........................15-3 ERVICE Supplies ........................15-3 Tools ..................................15-3 Expendable ................................15-3 Replaceable ................................. 15-3 Service Schedule Procedures ................... 15-3 Powder coat repair .............................. 15-3 Primer repair ................................ 15-4 Decorative paint repair ............................15-5 15-1...
Page 168: O Verview
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-12 are not alclad and must be primed to ensure corrosion resistance. Zinc Chromate has been the traditional primer used on aircraft aluminum.
Page 169: S Ervice
Rev.1 SERVICE ▲ WARNING: P AINT 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 ■...
Page 170 Rev.1 Tools Sandpaper Expendable Touch-up paint Replaceable None Service Rating Line Total area 4 in² or less - Owner and SPC Minimum Certification Total area greater than 4 in² - LSA-RM or A&P Additional References 1. Use coarse grit sandpaper to remove the entire area of loose, stained or cracked coating.
Page 171 Rev.1 ECORATIVE PAINT REPAIR ■ CAUTION: A NY SCRATCH THAT HAS PENETRATED TO THE METAL MUST BE CLEANED AND PRIMED PRIOR TO APPLYING DECORATIVE PAINT ● NOTE: W HEN PRIMING A REMOVABLE PART BETTER RESULTS CAN BE ACHIEVED BY REMOVING THE PART Tools Sandpaper Expendable...
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Page 173: Chapter 16 - Troubleshooting
Rev.1 CHAPTER 16 - TROUBLESHOOTING Symptom Possible Causes Related Chapter Recurring blown fuse Short in circuit ♦ Overloaded circuit ♦ Engine will turn over, Insufficient ignition source ♦ fails to start Insufficient fuel supply to engine ♦ Insufficient air supply to engine ♦...
Page 174 Rev.1 Symptom Possible Causes Related Chapter Vibration at idle Propeller installed incorrectly ♦ Idle RPM too low ♦ Carb. sycronization out of balance Rotax line maint. ♦ Engine suspension loose ♦ Vibration at specific Carburetor malfunction ♦ Ignition malfunction Rotax line maint. ♦...
Page 175: Chapter 17 - Feedback & Replacement Parts
To maintain the highest level of safety the FAA requires and Van’s Aircraft Inc. requests notification of any safety of flight issue, service or maintenance difficulty that could compromise airworthiness of the RV-12 aircraft. A feedback form is provided in the Supplement section of this manual.
Page 176: R Eplacement P Arts
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.
Page 177: S Ubstitute P Arts
Rev.4 SUBSTITUTE PARTS The following parts are approved for substitution. Either the original part or substitute part is acceptable for installation in the aircraft. Brake System F 271-N-04X02 Male Nylon Tee ↔ Van's FLF-00004 Male Nylon Tee ↔ MCMASTER- CARR 5779K204 ↔ LEGRIS 3103 56 11 Avionics System FN4MC-2 Nylon 1/4 Straight ↔...
Page 178 Rev.4 17-4...
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Page 180: Chapter 18 - Supplement
Rev.8 CHAPTER 18 - SUPPLEMENT ............................18-3 ERVICE CHEDULE CHECKLIST ..............................18-7 NSPECTION HECKLIST ............................18-23 LECTRICAL SYSTEM SCHEMATIC .....................................18-25 ................................18-27 EEDBACK 18-1...
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Page 182: S Ervice S Chedule
Rev.8 SERVICE SCHEDULE CHECKLIST Service What Action When Date Initial Aircraft Inspection Annual or 100 hours AST attach hinge Lubricate Annual or 100 hours 5-24 Battery Charge As needed 8-13 Battery terminals Clean As needed 8-13 Brake fluid Flush & replace 5 years Brake pedal components Lubricate...
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Page 184 Rev.8 SERVICE SCHEDULE CHECKLIST Service What Action When Date Initial Manifold Pressure Hose Replace 10 years or eng. ovhl. 12-16 Nose fork pivot Lubricate Annual or 100 hours 5-26 Nose wheel bearings Replace As needed 5-24 Wheel Balance Balance As needed 5-26 Oil Supply Hoses Replace...
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Page 186: I Nspection C Hecklist
Rev.8 INSPECTION CHECKLIST RV-12 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...
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Page 188 Rev.8 Oil Pressure & Temperature Pre-Values: Pressure_______ Temp______ Post-Values: Pressure_______ Temp______ Left and Right CHT (idle & operating temp) Pre-Values: Left_________ Right_________ Post-Values: Left_________ Right_________ Left and Right EGT (idle & operating temp) Pre-Values: Left_________ Right_________ Post-Values: Left_________ Right_________ Left and Right Wing Secure / Smooth operation of ailerons and flaps Brake System...
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Page 190 Rev.8 Notes: Cockpit Check Pass Fail Aft Face of Firewall Cracks / Deformation Canopy Latch Security / Cracks / Proper operation Fwd & Aft Canopy Cracks / Deformation / Deterioration Pre-Inspection procedure Step 1-5 (Page 3-3) Seats & Seat/Shoulder Harness Wear / Fraying Cockpit Control Markings Clear / Correct...
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Page 192 Rev.8 Cockpit Control markings Clear / Correct Control Panel Security / Connections Fuses Security / Condition / Spares Control Cable Links & Push / Pull Rods Tension / Wear / Fatigue Control Stops Security / Deformation / Alignment Flight Control Cables Swages / Kinks / Interference / Alignment Engine Control Cables Operation / Kinks / Interference / Alignment...
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Page 194 Rev.8 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 Also refer to current CFR 91.207 Propeller Refer to Sensenich Manual Pass Fail Spinner / Back-plate Cracks / Deformation...
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Page 196 Rev.8 Engine Refer to Rotax Manual Pass Fail Engine and components Comply with Rotax manufacturer inspection recommendations (Rotax Line Maintenance Manual) Firewall Forward Fasteners / Deformation / Corrosion Pass Fail Fwd Face of Firewall Deformation / Cracks / Unsealed holes Studs &...
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Page 198 Rev.8 Fuselage Fasteners / Corrosion / Deformation Pass Fail Skins Deformation / Cracks / Signs of Wear / Corrosion Footprint Area of Left & Right Wing Signs of Wear Bulkheads & Stringers Deformation / Cracks / Signs of Wear / Corrosion Left &...
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Page 200 Rev.8 Hinges & Rod Ends Free-play / Smooth Operation Component Skins Deformation / Cracks / Signs of Wear / Corrosion Control Cable Links & Push / Pull Tension / Wear / Fatigue Rods Control Stops Security / Deformation / Alignment Rear Spar Doubler Check for Gap Paperwork...
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Page 202 Rev.8 ELECTRICAL SYSTEM SCHEMATICS Refer to P. O. H. or http://www.vansaircraft.com/public/downloads.htm 18-23...
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Page 204: View
Rev.8 3-VIEW 18-25...
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Page 206: Feedback Form
Rev.8 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: 18-27...
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Page 208 Some aircraft maintenance may be performed by an "Approved Approved Owner Owner" found competent by Van's Aircraft. Approval will be for a specific task, person(s) and aircraft. Refers to the FAA Advisory Circular ‘Acceptable Methods, Techniques, and Practices – Aircraft Inspection and Repair.
Page 209 Rev.3 Engine EMS. Refers to the Dynon D-180, Dynon Skyview or Garmin G3X. The portion of the EFIS unit that compiles and displays engine Management System information. Extreme Heavily contaminated air; dust, bugs, smoke, debris, ash, sand, etc. or adverse climatic conditions conditions Flaperon A control surface that combines the aileron and flap functions into...
Page 210 Facility manufacturer. Pilot Operating POH. The handbook provided with the aircraft that introduces the systems and features that are included in the RV-12. Includes air Handbook and ground operating procedures and defines performance and weight and balance information. Simple or minor preservation operations and the replacement of...
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Page 212 Rev. 4 CHAPTER 20 - INDEX 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..3-12, 5-13 Anti-servo / trim tab ........5-6, 5-7 Inspection .............
Page 213 Rev. 4 Control cable Replacement ..........6-6 Control Stops ..........3-6 Control system ........... 6-1 Rod-End Lubrication ........6-9 Coolant ..........See Engine Cowl Hinge ........... 12-2, 12-16 Cowling Installation ............ 12-5 Removal ............12-4 Cylinder Removal ........... 12-18 Decorative paint ..........15-5 Dynon .........
Page 214 Rev. 4 Lift and Support..........1-16 Terminal Tab ..........8-14 Inspection ..........3-9 Fuselage Pins ............ 5-3 Fuses ..............8-6 Garmin ............9-2, 9-4 Gascolator Cleaning ............13-7 Installation ............ 13-7 Inspection ............3-9 Removal ............13-7 Harness, Shoulder ..........5-3 Inspection ............
Page 215 Rev. 4 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 ............. 3-11 Lubrication ........... 5-26 Removal ............5-21 Nose Wheel and Tire Bearings ............
Page 216 Replacement ..........6-7 Rudder Pedals Installation ............6-9 Removal ............6-8 Rudder ..............5-7 Inspection ............. 3-14 Removal ............5-18 RV-12 3-View ............18-25 Summary ............1-1 Safety ..............1-4 Feedback ............. 17-1 Feedback Form .......... 18-27 Sensenich.......... See Propeller Service Schedule ..........
Page 217 Rev. 4 Weight and Balance ......... 1-18 Wheel Bearings Main ............. 5-26 Nose ............. 5-25 Wing Attach Location Lubrication ....5-25 Fuselage Pins ..........5-25 Stub Spar and Rear Spar ......5-25 20-6...

Van's Aircraft RV-12 Maintenance Manual

Table of Contents

Chapter 1- General

Chapter 2- Service Schedule

Chapter 3 - Inspection

Chapter 4 - Structural Repairs

Chapter 5 - Structures

Chapter 6 - Flight Controls

Chapter 7 - Brake System

Chapter 8 - Electrical System

Chapter 9 - Instruments & Avionics

Chapter 10 - Utility Systems

Chapter 11 - Propeller

Chapter 12 - Firewall Forward

Chapter 13 - Fuel System

Chapter 14 - Exhaust System

Chapter 15 - Painting and Coatings

Chapter 16 - Troubleshooting

Chapter 17 - Feedback & Replacement Parts

Chapter 18 - Supplement

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Summary of Contents for Van's Aircraft RV-12