Engine Overhaul Manual
Jabiru Aircraft
Pty Ltd
Jabiru 2200 & 3300 Aircraft Engines
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Dated : 28/10/2014
Issued By: AS
Page: 87 of 201
L:\files\Manuals_For_Products\Engine_Manuals\Overhaul_Manual\JEM0001-7_Overhaul_Manual_DRAFT_(29_10_14).docx
5.13 Subassembly E
– Flywheel, Ignition Coils, Starter Motor And Alternator
5.13.1 Ignition Coils & Alternator
5.13.1.1 Mandatory Updates
Flywheel
– must be dowelled to the crankshaft with 6mm dowels and 5/16” or 3/8” (not ¼”) cap screws
– refer to Subassembly A (Section 5.9) for details of this modification. Note that early “Starfish” type
flywheel used 20mm long dowels while the previous assembly
and the current version “Starfish” use
24mm.
Ignition coils:
Shiny black coils marked “LEADING X” must be replaced.
Alternator: 3-phase alternators must be replaced.
Tachometer: sensors must be “hall effect” type or read from two dedicated tags fitted to the flywheel.
Senders which read directly from the starter ring gear teeth must be replaced.
5.13.1.2 Cleaning
Clean the flywheel with kerosene and dry.
Wipe all electrical components with a soft cloth; use a brush if necessary to dislodge dust from each
unit. Do not use chemical cleaners on any electrical components.
5.13.1.3 Inspection And Repair
Inspect the starter drive gear and the flywheel ring gear for chipped teeth: if any teeth are chipped or
missing then a new gear must be ordered. The ring gear may have either 99 or 101 teeth
– you must
specify the exact tooth count when reordering either gear. Note also that the engine backing plate is
specific for each ring gear
– i.e. a 99-tooth-compatible backing plate must be used with a 99 tooth ring
gear and vice versa for a 101 tooth part.
Magneto and alternator magnets must be tested using a prop bolt attached to a spring balance. Details
of the testing method and the required limits are given in Section 9.6.
Magnets that are weaker than this must be replaced. When replacing magnets the North (N) pole must
be oriented outwards on the flywheel. It is very rare for magnets to lose their strength but it can happen
if the magnets are overheated or subject to an impact.
Test the ignition coils as detailed in Section 9.6.
Test the resistance between the alternator poles and the resistance to ground as detailed in Section
Replace any units that fail to meet these values.
Visually inspect the alternator for signs of burning, rubbing, chafing or other damage. Replace if
damage is found. Disassembly is only required if damage is found.
In particular inspect the connectors on the output wires from the alternator. If there are indications of
excess heat these connectors must be removed and new, high-quality insulated female connectors
fitted. Ensure the new connectors are a tight fit when test-assembled with a male connector.
Figure 101
– Different Ignition Coil Models (Honda on Left, Jabiru on Right).
