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GENERAL MAINTENANCE & OPERATION MANUAL
FOR
JABIRU 5100 AIRCRAFT ENGINE















This Manual has been prepared as a guide to correctly operate, maintain and the
Jabiru 5100 engine.


Should you have any questions or doubts about the contents of this manual,
please contact your nearest certified Jabiru Dealer.

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Dated : 03/03/03
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2.1.

Dimensions and Weights.................................................................................... 6

2.2.

Normal Equipment.............................................................................................. 6

2.3.

Performance Data .............................................................................................. 6

2.4.

Fuel Consumption .............................................................................................. 6

2.5.

Fuel and Lubricant.............................................................................................. 7

2.6.

Cooling System .................................................................................................. 7

2.7.

Operating Speeds .............................................................................................. 7

4.1.

Pre-Start Checks................................................................................................ 9

4.2.

Starting Procedure ............................................................................................. 9

4.3.

Warming Up Period, Ground Test ...................................................................... 9

4.4.

Take-Off ............................................................................................................. 9

4.5.

Engine Stop...................................................................................................... 10

4.6.
10

4.7.

Engine Stop and Start During Flight ................................................................. 10

5.1.

Daily Checks .................................................................................................... 11

5.2.

Check After Initial 5, 10 & 15 Hours.................................................................. 11

5.3.

25 Hours Check................................................................................................ 12

5.4.

Hourly Service .................................................................................................. 12

5.5.

Engine Storage ................................................................................................ 12

5.6.

Operation in Winter .......................................................................................... 14

5.7.

Carburettor Icing .............................................................................................. 14

6.1.

6.1 Lubrication System .................................................................................... 16
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6.2.

Air Intake Filter ................................................................................................. 16

6.3.

Carburettor Adjustment .................................................................................... 16

6.4.

Compression Check ......................................................................................... 16

6.5.

Spark Plugs...................................................................................................... 17

6.6.

Exhaust System ............................................................................................... 17

6.7.

Tightening of Cylinder Heads ........................................................................... 17

6.8.

Tappet Adjustment ........................................................................................... 17

6.9.

Tachometer and Sender................................................................................... 17

7.1.

Engine Overhaul and TBO ............................................................................... 18

7.2.

ENGINE REMOVAL PROCEDURE.................................................................. 19





8.1.

AVAILABILITY OF SERVICE AND PARTS AFTER WARRANTY .................... 20

8.2.

UNAUTHORISED STATEMENTS IN RELATION TO JABIRU PRODUCTS .... 20

8.3.

WARRANTY ON JABIRU REPLACEMENT PARTS......................................... 20


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4 Stroke (5077cc)
8 Cylinder
Horizontally Opposed
One Central Camshaft
Pushrods
OHV
Ram Air Cooled
Wet Sump Lubrication
Direct Propeller Drive
Dual Transistorized Magneto Ignition
Integrated AC Generator
Electric Starter
Mechanical Fuel Pump
Pressure Compensating Carburettor (Bing Type 94/40)

It is said that "aircraft are designed around available engines".

Jabiru believes that the Jabiru range of very light engines will now offer new
opportunities for light aircraft designers, to develop a new generation of light
aircraft.

Jabiru engines are designed to be manufactured in small batch quantities using
the very latest Computer Numerically Controlled (CNC) machine centers. The
vast majority of the components are manufactured in Southern Queensland in a
network of high technology small companies.

Most parts are machined from solid billets of chrome molybdenum ally steel and
aluminium with smaller parts machined from larger parts as they are being made.
This minimises wastage and costs.

The propeller is direct crankshaft driven and does not use a reduction gearbox.
This facilitates the engines light-weight design and keeps maintenance costs to a
minimum. The crankshaft features a removable propeller flange which enables
the easy replacement of the front crankshaft seal and provides for a propeller
shaft extension to be fitted, should this be required for particular applications.

Various components of the engines are sourced from many Suppliers.

An integral alternator using rare earth magnets provides alternating current for
battery charging and electrical accessory drive. The alternator is attached to the
flywheel and is driven directly by the crankshaft. The ignition system is a
transistorised electronic system; two fixed coils mounted adjacent to the flywheel
are energised by rare earth magnets attached to the flywheel. The passing of
the coils by the magnets creates the high voltage current which is then
transported by high tension leads to the centre post of two distributors (which are
simply rotors and caps) before distribution to spark plugs. The ignition system is REVISION
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fixed timing and, therefore, removes the need for timing adjustment. The ignition
system is fully redundant, self-generating and does not depend on battery power.

The crankshaft is designed with a double bearing at the propeller flange end and
a main bearing between each big end; it therefore does not have flying webs.
Thrust bearings are located for and aft of the front double bearing allowing either
tractor or pusher installation.

Pistons are sourced in Australia and are re-machined to include a piston pin
circlip groove. They are fitted with 3 rings, the top and second rings being cast
iron to complement the chrome molybdenum cylinder bores. Valves are purpose
manufactured for the Jabiru engine in England.

The oil pump is direct mounted on the camshaft and incorporating a small
automotive spin-on filter, provides engine lubrication. An oil cooler adapter is
provided. Most installations require an oil cooler to meet oil temperature limits.

The standard engines are supplied with two RAMAIR cooling ducts, which have
been developed by Jabiru to facilitate the cooling of the engine and direct air
from the propeller to the critical areas of the engine, particularly the cylinder
heads and barrels. The fitment of these RAMAIR cooling ducts is a great bonus
for the home builder or engine installer, as they obviate the need to design and
manufacture baffles and the establishment of a plennum chamber, which is the
traditional method of cooling air-cooled aircraft engines. The fact that these
baffles and plenum chamber are not required also ensures a "cleaner" engine
installation, which in turn makes maintenance and inspection of the engine and
engine component easier. So the hard work of engine installation has largely
been done for you by the Jabiru design team. RAMAIR ducts are available for
tractor or pusher configurations. Special ducts are available for certain
installations.

Non fitment of these Ducts can void your warranty.

The engine is fitted with a 1.4 kW starter motor, this provides very effective
starting. The engine has very low vibration levels, however it is also supported by
four large rubber shock mounts attached to the engine mounts.

The fuel induction system comprises of two BING pressure compensating
carburettor. Following carburetion, the fuel/air mixture is transported through a
swept plenum chamber bolted to the side of the crankcase, in which the mixture
is warmed prior to entering short induction tubes attached to the cylinder heads.

An effective stainless steel exhaust and muffler