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Maintenance Manual This Maintenance Manual belongs to aircraft serial numbers:

SP = MS9001 - MS9999 FT = MF8001 - MF8999

October 23, 2012

October 23, 2012

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TABLE OF CONTENTS TABLE OF CONTENTS..................................................................................................................... 2  

Section I Revision Table.................................................................................................................. 4  

Section II Table of Figures ................................................................................................................ 4  

1   GENERAL.................................................................................................................................... 5  

About this Manual ........................................................................................................................ 5  

Terms and Definitions ................................................................................................................. 5  

Approved Equipment List .......................................................................................................... 5  

Required Instruments ................................................................................................................. 5  

Optional Instruments and Avionics........................................................................................... 5  

Required/Standard Equipment ................................................................................................. 6  

Optional Equipment .................................................................................................................... 6  

Basic Guidance for All Maintenance and Repair Work....................................................... 6  

Level of Certification Required to Perform Maintenance ................................................... 7  

Type of Maintenance ................................................................................................................... 7  

Sources to Purchase Parts ........................................................................................................ 8  

Disposable Replacement Parts................................................................................................. 9  

Engine Specifications – Subaru MAV EJ22 (for reference only)......................................... 9  

Engine Specifications – Subaru MAV EJ25 (for reference only)......................................... 9  

Weight and Balance Information .............................................................................................. 9  

Tire Inflation Pressures............................................................................................................... 9  

Approved Oils and Capacities ................................................................................................ 10  

Recommended Fastener Torque Values .............................................................................. 10  

General Safety Information ...................................................................................................... 11  

Reporting Possible Safety of Flight Concerns ................................................................... 11  

2   INSPECTIONS .......................................................................................................................... 12  

Periodic Inspections .................................................................................................................. 12  

Replacement Schedule ............................................................................................................. 12  

ANNUAL CONDITION INSPECTION ....................................................................................... 13  

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Annual Condition Inspection Checklist ................................................................................ 14  

3   STRUCTURES.......................................................................................................................... 15  

4   ENGINE ..................................................................................................................................... 22  

5   FUEL SYSTEM ......................................................................................................................... 24  

6   PROPELLER ............................................................................................................................. 24  

7   UTILITY SYSTEMS .................................................................................................................. 25  

8   INSTRUMENTS AND AVIONICS........................................................................................... 27  

9   ELECTRICAL SYSTEMS ........................................................................................................ 27  

10   STRUCTURAL REPAIRS.................................................................................................... 27  

11   PAINTING AND COATINGS............................................................................................... 27  

12   REVISIONS TO MAINTENANCE MANUAL ..................................................................... 28  

13   FEEDBACK FORM............................................................................................................... 28  

14   SAFETY DIRECTIVES ........................................................................................................ 30  

15   ORIGINAL AND BACKUP DOCUMENT LOCATION: .................................................... 31  

Appendix I .......................................................................................................................................... 31  

Appendix II......................................................................................................................................... 32  

Appendix III........................................................................................................................................ 42  

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Section I Revision Table Rev Level Reason for change Date Released Approved

NC Initial Release 6/28/2010 TT 1 Production Release Update 7/8/2011 TT 2 Production Release Update 2/8/2012 TT 3 Production Release Update 10/23/2012 TT

Section II Table of Figures

Figure 2: Rear Suspension and Tire (rear view) .......................................................................... 33  Figure 3: Front Suspension ....................................................................................................... 33  Figure 4: Rear Suspension and Tire ........................................................................................... 33  Figure 5: Front Tire .................................................................................................................. 33  Figure 7: Ground Drive Axle ...................................................................................................... 35  Figure 8: Drive Train................................................................................................................. 35  Figure 9: Ground Drive Continuously Variable Transmission......................................................... 35  Figure 10: Parachute Bottom View............................................................................................. 36  Figure 11: Parachute Side View ................................................................................................. 36  Figure 12: Parachute Front View................................................................................................ 36  Figure 13: Steering Wheel......................................................................................................... 37  Figure 14: Rack and Pinion Assembly......................................................................................... 37  Figure 15: Brake and Accelerator Pedals .................................................................................... 37  Figure 16: Manual Override Pedals, Linear Stepper Motors, Wiring Connectors, Rigging ............... 38  Figure 17: Steering Input Sensor Located on Rack and Pinion...................................................... 38  Figure 18. Fuel Tank, Strainer, and Outlet ................................................................................... 39  Figure 19: Fuel Tank, In-Line Pumps, Fuel Filter ......................................................................... 39  Figure 20. Fuel System Schematic .............................................................................................. 39  Figure 21: Subaru MAV EJ22 Engine......................................................................................... 40  Figure 22. Subaru MAV EJ25 Engine ........................................................................................... 40  Figure 23: Propeller .................................................................................................................. 41  Table 1. Disposable Replacement Parts........................................................................................ 9  Table 2. Propeller Cogged Belt Tension Values ........................................................................... 18  Table 4: Maverick Wiring Diagram/Table (With ECU 1) – Also applies for fly by wire steering system................................................................................................................................................ 43  

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1 GENERAL About this Manual

IMPORTANT: REVIEW ALL MATERIAL IN THIS MANUAL PRIOR TO MAINTAINING YOUR Maverick!

This manual is provided by Beyond Roads to communicate various procedures and methods for maintaining your Maverick aircraft. Maintenance must be done consistently to keep your aircraft in flying condition and to promote the safety of each flight. Before performing any maintenance, check www.Mavericklsa.com for a new revision of this Maintenance Manual. All maintenance should follow and is acceptable if performed according to FAA AC43.13-1B unless it contradicts the practices of this manual, in which case the practices of this manual shall be followed. This manual shall apply to all makes and models of Mavericks manufactured by Beyond Roads, and practices that differ based on model or make will be noted as such. Terms and Definitions

Manufacturer: generally refers to Beyond Roads, unless referring to the manufacturer of a specific component. Beyond Roads: Beyond Roads, LLC. ELSA: Experimental Light Sport Aircraft SLSA: Special Light Sport Aircraft PPC: Powered Parachute About the Aircraft The Maverick is a powered-parachute Light Sport Aircraft (LSA). The two-seat chassis and suspension members are made primarily of welded steel tubing and the wing is an elliptical ram-air type parachute (parafoil). It features a mast and spar wing deployment system, electronic steering (with redundant conventional steering controls), and basic engine instrumentation. The aircraft is configured with four wheels, independent suspension, a Subaru MAV engine, and a transmission capable of powering a propeller (in pusher configuration) or the rear wheels for ground mobility.

Approved Equipment List

Required Instruments -EIS (Engine Information System) monitoring fuel level, oil pressure, coolant temperature and engine RPM -Engine Kill Switch – The key is used as a kill switch. To kill the engine, turn the key to the straight up and down position.

Optional Instruments and Avionics  -Mode C Transponder, compliant to FAA requirements -P.S. Engineering (PM1000) intercom and wiring harness -Garmin GPS (Aera 500 panel-mounted, air and ground) and wiring harness -Garmin SL40 (“flip-flop”) communication radio and wiring harness -Icom portable communication radio -Emergency Transmitter Locator (ELT)

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Required/Standard Equipment -Windshield -Carbon Fiber Hood -Occupant safety restraint system: All occupants have at least a 3 point attach system with a lap belt and two shoulder harnesses for flight operations. -Head lights, brake lights, turn signal lights, parking brake, horn

Optional Equipment -“Tuxedo”: Sunbrella water-repellant fabric with clear vinyl side windows, standard color black with custom colors optional -High-speed tires on aluminum rims, 24”X5” (Front) 26”X8” (Rear) -Off-Road tires on aluminum rims, 25”X8” (Front and Rear) -Fenders – standard color black, custom colors available -Custom-color, powder-coated frame paint (standard color black) -Custom-color, painted hood (standard no painting) -Rosen sun visors and mounting brackets

Basic Guidance for All Maintenance and Repair Work

Supporting the aircraft: Caution: Parts being worked on may be part of the supporting structure. Each step that removes a bolt or other part must first be assessed to assure that the subsequent assemblies will be stable and supported. Jacking in the rear is allowed directly under the outboard most, lowest points on the frame where the lower engine mount frames are bolted to the main chassis. Jacking in the front is allowed on the outboard most, lowest tubes of the main chassis forward of the most aft attachment point of the front suspension A-frames.

Fluid Systems: The three primary fluids are engine oil, fuel and engine coolant. Hydraulic fluid (brakes) and transaxle oil are also used. For engine oil see drain points presented in the engine manual - the primary drain point is at the bottom of the oil pan. For fuel, the drain sump is on the bottom of the fuel tank. For coolant, there is a plug in the bottom of the radiator or a coolant hose at a low point in the system may be detached to drain coolant.

Electrical Systems: In process of working on the aircraft’s electrical system, the negative battery lead should be disconnected to assure that no short circuits are caused. In addition, the main harness should be disconnected from the fly-by-wire steering system.

Verification Assessment: Although it may not be stated in the following work areas, it is the responsibility of the person doing the maintenance, repairs, or alterations to complete their work by doing a functional evaluation sufficient to guarantee that the maintenance/repairs will function properly. The systems should function according to the manufacturer’s specification or at least equally well as it did before the alteration was performed or before the problem that was fixed. Contact the manufacturer for approval before performing maintenance for which instructions are not included or provided for in this manual.

Tools Required: While some specific tools may be called for in the individual work areas of this manual, it is assumed that the following tools are available for any given task:

SAE wrench set Metric wrench set SAE socket and ratchet set Metric socket and ratchet set #1, #2 and #3 Phillips screw drivers Straight screw driver

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Drift punch Hammer Pop rivet puller Safety wire pliers Safety wire Cotter pins SAE Allen wrench set Metric Allen wrench set Torque Wrench

Level of Certification Required to Perform Maintenance

Listed in order of qualification, from lowest to highest:

Owner: Responsible owner who holds a pilot certificate but who has not necessarily received any specific authorized training. This individual is not required to hold specific authorized training certificate but should be mechanically inclined. Unless this maintenance manual directs otherwise, FAA regulations authorize SLSA aircraft owners who hold at least a sport pilot certificate to perform maintenance as outlines in 14 CFR part 43. Note: ELSA do not require the individual performing maintenance to hold any FAA airman certificate in the U.S., so. for maintenance on an ELSA, items requiring ‘Owner’ certification may not require that the individual own the aircraft being serviced or even hold a pilot certificate.

LSA Repairman Inspection: Items that can be expected to be completed on an ELSA by a responsible owner, who holds an FAA repairman certificate (light sport aircraft), with an inspection rating or equivalent. That is, an owner who is a U.S. FAA-certificated repairman (light sport aircraft) with an inspection rating as defined by 14 CFR Part 65, authorized to perform the annual condition inspection on ELSA, or an equivalent rating issued by other civil aviation authorities. LSA Repairman Maintenance: Items that can be expected to be completed on a SLSA by a responsible individual, who holds a FAA repairman certificate (light sport aircraft), with a maintenance rating or equivalent. That is, an individual who is a U.S. FAA-certificated repairman (light sport aircraft) with a maintenance rating as defined by 14 CFR Part 65, authorized to perform line maintenance on aircraft certificated as SLSA aircraft and authorized to perform the annual condition/100-h inspection on an LSA, or an equivalent rating issued by other civil aviation authorities. A&P: Items that can be expected to be completed by a responsible individual who holds a mechanic certificate with airframe or power plant ratings, or both, or equivalent. That is, an airframe and power plant mechanic as defined by 14 CFR Part 65 in the U.S. or equivalent certification in other countries. This individual may perform annual inspections and any maintenance or repairs they are qualified for as an A&P. Task Specific: Items that can be expected to be completed by a responsible individual who holds either a mechanic certificate or a repairman certificate and has received task specific training to perform the task. The specific training required must be as specified in this manual or be an equivalent. Engine overhaul or repair and wing repair/replacement is limited to those facilities approved specifically by Beyond Roads. Please contact Beyond Roads for information on an approved facility in your area.

Type of Maintenance

Line Maintenance: any repair, maintenance, scheduled checks, servicing, inspections, or

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alterations not considered heavy maintenance that is approved by the manufacturer and is specified in this manufacturer’s maintenance manual. Heavy Maintenance: any maintenance, inspection, repair, or alteration a manufacturer has designated that requires specialized training, equipment, or facilities. Major repair, Alteration, or Maintenance: any repair, alteration, or maintenance for which instructions to complete the task excluded from this maintenance manual.

Sources to Purchase Parts

Parts listed with outside vendor/manufacturer part numbers or sufficient specifications for purchase in the “Disposable Replacement Parts” and “Approved Oils and Capacities” sections of this manual may be purchased from any reputable vendor. Contact Beyond Roads for all other replacement parts, including those with Beyond Roads part numbers. Find current contact information at Mavericklsa.com. Additional suppliers may eventually be qualified and will then be shown here.

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Disposable Replacement Parts

For Engine: Subaru MAV EJ22 Subaru MAV EJ25 a) Transaxle Oil: SAE 85W90 API/GL-4 b) Oil Filter: Purolator # PL14460 or

equivalent Purolator # PL14620 or equivalent

c) Air Filter: NAPA # 2110 or equivalent K&N # E-3600 or equivalent

d) Fuel Filter: Beyond Roads Part # 405130 1. Standard: All tires 25x8.00-12 e) Tires: 2. Optional: Front: 24x5.00R15LT; Rear: 26x8.00R15LT (Note: May increase “empty weight”, depending on tire choice)

f) CVT Drive Belt: Maverick Part # 200130 g) Main Shaft to CVT Belt: Maverick Part # 200120 h) Prop Drive Belt: Maverick Part # 200160 h) Nyloc Nuts: Use appropriate AN hardware i) Brake Fluid: Any DOT 3 or DOT 4 rated brake fluid

Table 1. Disposable Replacement Parts

Engine Specifications – Subaru MAV EJ22 (for reference only)

• Displacement: 2212 cm³ • Bore: 96.9 mm • Stroke: 75.0 mm • Compression Ratio: 9.5:1 - 9.7:1 • Valve train: SOHC • Fuel Delivery: Carbureted • Horsepower: 127 HP (95 kW) @ 5000 rpm

Engine Specifications – Subaru MAV EJ25 (for reference only)

• Displacement: 2457 cm • Bore: 99.5 mm • Stroke: 79 mm • Compression Ratio: 10.0:1 • Valve train: SOHC • Fuel Delivery: Fuel Injected • Horsepower: 190 HP (142 kW) @ 4900 rpm

Weight and Balance Information

E-LSA/SLSA SLSA with FAA Exemption No. 10299

Empty Weight (lbs) 987 987 Max Gross Weight (lbs) 1320 1430 Useful Load (lbs) 333 443

Refer to POH (Beyond Roads Document #500401) for balance and CG adjustment information. Tire Inflation Pressures

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Standard Tires: 15 psi (cold) to start, then adjust based on operating conditions for handling and traction performance. DO NOT EXCEED TIRE MANUFACTURER’S PRESSURE AND LOADING GUIDELINES. Optional Tires: 10 psi front, 30 psi rear (both cold). Adjust based on operating conditions for traction and handling performance. DO NOT EXCEED TIRE MANUFACTURER’S PRESSURE AND LOADING GUIDELINES.

Approved Oils and Capacities

a) Engine Oil and Capacity: 4.2 US Quarts if replacing engine oil and filter. 4.0 US Quarts if only replacing engine oil.

Recommended oil: Those with API standard SM “Energy Conserving” logo. Those with ILSAC standard GF-4 “starburst” mark on container.

Normal Operating Conditions:

High Temperature or Severe Environment Operation: API Standard: SM or SL; SAE Viscosity #: 30, 40, 10W-50, 20W-40, 20W-50

b) Transaxle Oil: SAE 85W90 API/GL-4 – Fill to ½ in. below check plug. Recommended Fastener Torque Values

Use aircraft torque values (See FAA AC43.13-1B) where applicable. For propeller, follow manufacturer’s guidelines. For all engine bolts, follow standard factory Subaru torque guidelines. In all cases, follow this manual if there is any contradiction between it and another standard. Joints subject to rotation: Tighten until there is little gap, then the fastener must be a castellated nut locked with a cotter key or equivalent. Joints not specifying a torque: Tighten until the washer (if present) will not turn (until the bolt/nut will not turn in the assembly if there is no washer) and then the nut should be tightened ¼ turn more. If this is not a rotating joint, a nyloc nut will be sufficient, castellated nuts with cotter keys are acceptable. Joints having a torque value specified: Torque as specified on either the drawing or in the maintenance manual. These will usually be in the area of the motor, gear box, propeller or similar high-load parts. Warning: DO NOT deform tubing by over tightening. If following recommended torque values or manufacturer’s torque guidelines results in the onset of tubing deformation, stop before deforming the tube and contact the manufacturer. Wheel Lug Nuts: 55 ft*lb (40.6 N*m)

Temperature (°C) -30 -20 -15 0 15 30 40 (°F) -22 -4 5 32 59 86 104 SAE Viscosity

5W-30

10W-30, 10W-40, 10W-50

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General Safety Information

Drug and Alcohol Use: Do not mix alcohol consumption or drug use with the assembly, operation, or maintenance of your aircraft.

Locking Nuts: All nyloc (nuts with a nylon locking insert held securely in place) or steel locking nuts require 1 to 3 threads of the bolt showing past the nut past the nut. A self-locking nut can be reused as long as a wrench is required to turn it onto the bolt. If it can be hand tightened, however, replace the nut. If in doubt follow FAA AC43.13-1B chapter 7.

Difficulty with Bolt Fit: First make sure the difficulty is not due to misalignment, an incorrect part, or an incorrect bolt. If necessary use a drift or pin punch to align. If misalignment is not the cause of the difficulty, it is okay to lightly ream the hole with a drill bit or reamer the same size of the hole. Only ream enough to get the bolt through.

Handling Cables: Do not leave cables where they might be stepped on and damaged. Also, do not bend or bind them any tighter than the configuration in which they were shipped.

Parachute and Parachute Lines: When handling parachute lines, BE SURE that they are not stepped on. This can introduce dirt and sand into the lines which can cause dramatic strength reduction and premature failure. Do not step on the parachute fabric and avoid pinching it between metal or other hard parts or snagging it on any sharp points as this can result in damage, deterioration, and loss of strength. Store the parachute in the manufacturer provided cover to avoid prolonged UV exposure from the sun. If wet or damp, allow the parachute to dry completely before storage to avoid damage.

Reporting Possible Safety of Flight Concerns

For reporting safety of flight concerns found during inspection/maintenance see FEEDBACK FORM section for details.

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2 INSPECTIONS Periodic Inspections

To be performed as often as specified in item or as often as specified in list, whichever is more often. All official inspections require the inspector to have a certification of LSA Repairman Inspection or higher. 25 HOUR/MONTHLY

1. Tire Wear/ Pressure 2. Propeller balance, propeller pitch, and torque of all bolts. Re-torque bolts after the first hour of

operation, and then every 5-10 hours for the first 25 hours of operation. Then check every 25 hours of operation.

3. Coolant Fluid Levels and condition (any foreign matter or oil in system) 4. Brakes – fluid level and pad wear; inspect at every 50 hours after first 25 hours 5. Steering system 6. Drive system belts

50 HOURS

1. Inspect engine area for leaks or loose fasteners 2. Inspect drive system belts for excessive wear 3. Transmission fluid level and condition.

300 HOURS

1. Inspect all vibration isolators (engine mounts, transaxle mounts, etc.) and replace if necessary

2. Inspect Throttle cables and replace if necessary 3. Inspect Radiator lines and replace if necessary

Replacement Schedule

It is recommended that the following items be replaced at the given intervals. Refer to an applicable Subaru engine maintenance manual applicable for additional replacement requirements. 50 HOURS

1. Change Engine Oil and Filter 2. Brake Pads – if necessary (or after first 25 hour inspection)

300 HOURS

4. Vibration isolators – if necessary 5. Throttle cables - if necessary 6. Radiator lines - if necessary 7. Electric Fuel Pumps (both) 8. Drive System Belts 9. Overhaul Transmission

2 YEARS

1. Mandatory: contact Beyond Roads for parachute assessment by Beyond Roads or their accepted personnel. The parachute reviewer shall specify intervals for test after this based on the parachute condition. Assessment shall include tests/evaluations of porosity, strength, and deformation according to manufacturer standards or, if non-contradictory, industry accepted practices.

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Annual Condition Inspection

The following items should be inspected and/or replaced if necessary ANNUALY or every 100 hours of service, whichever occurs first.

1. Perform Annual Inspection in accordance with FAR 43 Appendix D as applicable 2. Engine Compression 3. Engine Vibration Isolators (engine mounts) 4. Main (all) wheel bearings, inspect and replace if necessary 5. Throttle cable and linkage 6. Exhaust system 7. Fuel line 8. Propeller hub through-bolts 9. Propeller assembly 10. Inspect parachute lines and cloth for excessive wear, chafing or tears/holes – contact Beyond

Roads for parachute service 11. Radiator hoses 12. Redrive transmission, systems and belts 13. Remove and clean fuel filter and strainer 14. Inspect entire airframe for cracks, deformation, corrosion or wear 15. Inspect all fasteners for correct torque 16. Inspection all wiring for chafing and appropriate support and restraint 17. Check manufacturer’s online maintenance website for applicable service letters and

necessary modifications or revisions, and comply as necessary 18. Record Annual Inspection in Aircraft Maintenance Records

This is a sample form for recording of Annual or 100 Hour inspection (next page). The specifics shown above are to be recorded as inspected by checking “pass” or by checking “fail” and showing how it was corrected.

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Annual Condition Inspection Checklist

Aircraft Make/Model: __________________ S/N: _________________ Engine Make/Model: ___________________ S/N: _________________ Date of Inspection:_____________ TT Airframe: _______________________ TT Engine: _________________ Scope and Detail of Items (As Applicable to the Particular Aircraft) to be Included in Annual and 100-Hour Inspections: (a) Each person performing an annual or 100-hour inspection shall, before that inspection, remove or open all necessary inspection plates, access doors, fairing, and cowling. He shall thoroughly clean the aircraft and aircraft engine after initial visual inspection for oil, exhaust, or other leaks as applicable is completed. (b) Each person performing an annual or 100-hour inspection shall inspect (where applicable) the following components of the fuselage and hull group: Pass Fail (1) Fabric and skin-for deterioration, distortion, other evidence of failure, and defective or insecure attachment of fittings. Pass Fail (2) Systems and components-for improper installation, apparent defects, and unsatisfactory operation. (c) Each person performing an annual or 100-h inspection shall inspect (where applicable) the following components of the cabin and cockpit group: Pass Fail (1) Generally for uncleanliness and loose equipment that might foul the controls. Pass Fail (2) Seats and safety belts/for poor condition and apparent defects. Pass Fail (3) Windows and windshields/for deterioration and breakage. Pass Fail (4) Instruments/for poor condition, mounting, marking, and (where practicable) improper operation. Pass Fail (5) Flight and engine controls/for improper installation and improper operation. Pass Fail (6) Batteries/for improper installation and improper charge. Pass Fail (7) All systems/for improper installation, poor general condition, apparent and obvious defects, and insecurity of attachment. (d) Each person performing an annual or 100-hour inspection shall inspect (where applicable) components of the engine and nacelle group as follows: Pass Fail (1) Engine section/for visual evidence of excessive oil, fuel, or hydraulic leaks, and sources of such leaks. Pass Fail (2) Studs and nuts/for improper torqueing and obvious defects. Pass Fail (3) Internal engine/for cylinder compression and for metal particles or foreign matter on screens and sump drain plugs. If there is weak cylinder compression, for improper internal condition and improper internal tolerances. Pass Fail (4) Engine components/for cracks, looseness of mounting, and looseness of engine to mount. Pass Fail (5) Flexible vibration dampeners/for poor condition and deterioration. Pass Fail (6) Engine controls/for defects, improper travel, and improper safetying. Pass Fail (7) Lines, hoses, and clamps/for leaks, improper condition and looseness. Pass Fail (8) Exhaust stacks/for cracks, defects, and improper attachment. Pass Fail (9) Accessories/for apparent defects in security of mounting. Pass Fail (10) All systems/for improper installation, poor general condition, defects, and insecure attachment. Pass Fail (11) Engine Cowling/for fabric deterioration and defects, loose or damages hardware, and wear or defects in frame members. (e) Each person performing an annual or 100-hour inspection shall inspect (where applicable) the following components of the landing gear group: Pass Fail (1) All units/for poor condition and insecurity of attachment. Pass Fail (2) Shock absorbing devices/for improper air pressure. Pass Fail (3) Linkages, trusses, and members/for undue or excessive wear fatigue, and distortion. Pass Fail (4) Retracting and locking mechanism/for improper operation. Pass Fail (5) Hydraulic lines/for leakage. Pass Fail (6) Electrical system/for chafing and improper operation of switches. Pass Fail (7) Wheels/for cracks, defects, and condition of bearings. Pass Fail (8) Tires/for wear and cuts. Pass Fail (9) Brakes/for improper adjustment. Pass Fail (10) Floats and skis/for insecure attachment and obvious or apparent defects. Pass Fail (f) Each person performing an annual or 100-hour inspection shall inspect (where applicable) all components of the wing and center section assembly for poor general condition, fabric or skin deterioration, distortion, evidence of failure, and insecurity of attachment. Pass Fail (g) Each person performing an annual or 100-hour inspection shall inspect (where applicable) all components and systems that make up the complete empennage assembly for poor general condition, fabric or skin deterioration, distortion, evidence of failure, insecure attachment, improper component installation, and improper component operation. (h) Each person performing an annual or 100-hour inspection shall inspect (where applicable) the following components of the propeller group: Pass Fail (1) Propeller assembly/for cracks, nicks, binds, bolt torque. Pass Fail (2) Bolts/for improper torqueing and lack of safetying. (i) Each person performing an annual or 100-hour inspection shall inspect (where applicable) the following components of the radio group: Pass Fail (1) Radio and electronic equipment/for improper installation and insecure mounting. Pass Fail (2) Wiring and conduits/for improper routing, insecure mounting, and obvious defects. Pass Fail (3) Bonding and shielding/for improper installation and poor condition. Pass Fail (4) Antenna including trailing antenna/for poor condition, insecure mounting, and improper operation. Pass Fail (j) Each person performing an annual or 100-hour inspection shall inspect (where applicable) each installed piece of optional equipment on this listing for improper installation and improper operation. Pass Fail Option number one Pass Fail Option number two Pass Fail Option number three Pass Fail Option number four Pass Fail (k) Each person performing an annual or 100-hour inspection shall remove and inspect the ELT installed for proper operation of the “G” switch and calendar date currency of the batteries installed in accordance with FAA Advisory Circular 91-44 current revision. Notes and explanation of unairworthy items found (attach more information as needed): Signed ________________________________

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3 STRUCTURES 3.0 Frame (Cart/Empennage)

3.0.1 Description: The frame is comprised mainly of welded 4130 steel tubes with welded on tabs and brackets. The main chassis bolts to the lower and upper engine mount portions and the drag struts for the rear suspension, A-arms for the front suspension, and CG adjustment mechanisms are bolted to the frame. Cables on either side connect the CG adjustment mechanism to the frame. The pilot seat is supported by the bulkhead behind it and tubes and in the floor beneath, with passenger restraint seat belts connecting to the same locations. The rear passenger seat is supported by the gas tank and the bulkhead behind it, with passenger restraints in the bulkhead behind the seat.

3.0.2 Inspection: Inspect security of fasteners holding frame and drive system together. Visually inspect frame for bending, cracking, or fatigue. If any of these are present DO NOT fly or drive as they may precede failure of the frame. Contact the manufacturer. Especially inspect connection points and surrounding frame area for the suspension and wing. Note that paint and coatings can ide small cracks or deformation and that very small cracks in coatings may be indicative of deformation in the metal beneath the coating. Cables and hardware they connect to, as well as hardware in the CG adjustment mechanism (especially eyebolts) should not sound and undeformed. Inspect the thimbles and swages on the cables for thimble deformation (indicating overloading or beginning of failure) and cable slipping or fraying. No special tools are required to accomplish this task. No parts are needed to perform this task.

3.0.3 Maintenance, Repair, and Alteration: All services MUST be performed by the manufacturer or manufacturer approved facility or personnel. Owners require no special tools, instructions, parts, or inspection procedures for these services. Manufacturer will test/inspect services.

3.1 Landing Gear (Wheels and Suspension)

3.1.1 Description: The front suspension system includes four a-frame suspension arms, two air shocks, the front two wheels and the suspension/wheel connection points. The rear suspension system includes two struts, the rear two wheels, two rear axles connecting the wheels and transaxle, two air shocks, and the suspension/wheel connection points. See images in Appendix 2.

3.1.2 Inspection:

3.1.2.1 Special Tools, :

3.1.2.2 Welded Tube Assemblies: All bolts should be secure and the A-frames and struts in good condition. Rod end bearings should have no more than half of the threaded length on the stud showing, should not be bent or deformed, and balls should allow free motion with minimal slop. No special tools or parts are required to accomplish this task.

3.1.2.3 Bearing Holders, Hubs, Knuckles: All bearing holders, hubs, adapters, steering knuckles, and miscellaneous joining parts should be undeformed, allow full range of motion of the shock assemblies, and hold all bolts and parts tightly. No special tools or parts are required to accomplish this task.

3.1.2.4 Shock Absorbers/Springs: Refer to the shock manufacturer’s manual. No special tools or parts are required to accomplish this task unless otherwise specified.

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3.1.2.5 Wheels and Tires: Tires should have a fair amount of tread showing and have no major cuts or cracks. Inspect for even wear across tire width and circumference. Replace tire if less than 2/32” (1.6 mm) of tread remain (depth of shallowest indentation in tread pattern). Tires positions should be changed if wear on front tires or on back tires is not even. If using optional tires switch the sides the tires are on. If using standard tires, switch the right front with left rear tire and left front with right rear tire (unless this would cause wear in the same location it had been, in which case switch the tires to positions that would cause wear in different positions). Valve stems should hold pressure and be operational. Rims should have a smooth surface where the tire bead sits. No special tools or parts are required to accomplish this task.

3.1.3 Maintenance, Repair, and Alteration:

3.1.3.1 Checking/Adjusting Shock pressure

3.1.3.1.1 Recommended Special Tools: Shock Pump

3.1.3.1.2 Required Parts: None

3.1.3.1.3 Type of Maintenance: Line

3.1.3.1.4 Certification Required: Owner through A&P

3.1.3.1.5 Instructions:

3.1.3.1.5.1 Remove the air valve cap from the shock

3.1.3.1.5.2 Thread the pump’s valve chuck onto the shock’s air valve until pressure registers on the pump gauge. This takes approx. 6 turns. Do not over tighten pump on air valve, as this will damage the pumps chuck seal.

3.1.3.1.5.2.1 Stroke the pump a few cycles. The pressure should increase slowly. If pressure increases rapidly check to make sure the pump is properly fitted and tightened onto the air valve.

3.1.3.1.5.2.2 Pump to the desired pressure setting. Normal pressure range is 50 to 300 psi for front and 45 to 150 psi for rear. Do not exceed shock manufacturers guidelines for pressure settings or travel. You can decrease pressure by pushing the black bleed valve. Pushing the bleed valve half way down and holding it there will allow pressure to escape from the pump and shock. Pushing the bleed valve all the way down and releasing it will allow only a small amount of pressure to escape. When unthreading the pump from the air valve fitting, the sound of the air loss is from the pump hose, not from the shock.

3.1.3.1.5.2.3 Replace the air valve cap.

3.1.3.1.6 Test/Inspect: Visually confirm that the tires sit flat.

3.1.3.2 Changing Tires

3.1.3.2.1 Recommended Special Tools:

Jack sufficient to lift assembly

Lug Wrench

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Torque wrench (if available)

3.1.3.2.2 Required Parts:

Replacement tire on wheel (wheel assembly)

3.1.3.2.3 Type of maintenance: Line

3.1.3.2.4 Certification Required: Owner through A&P

3.1.3.2.5 Procedure

3.1.3.2.5.1 With tire on ground, loosen lug nuts.

3.1.3.2.5.2 Chock rear wheels when jacking the front of the vehicle, chock front tires when jacking the rear of the vehicle.

3.1.3.2.5.3 Jack from acceptable jack point see “Basic Guidance for All Maintenance and Repair Work” section of this manual.

3.1.3.2.5.4 Remove lug nuts.

3.1.3.2.5.5 Replace wheel with new assembly.

3.1.3.2.5.6 Hand tighten lug nuts

3.1.3.2.5.7 Tighten Lug nuts as practical off ground.

3.1.3.2.5.8 Lower vehicle.

3.1.3.2.5.9 Tighten lug according to torque specification.

3.1.3.2.6 Test/Inspect: Re-check torque on lug nuts with torque wrench.

3.2 Drive System

3.2.1 Description: The drive system is comprised of two cogged drive belts, one friction drive belt, four major shafts, two drive axles, three aluminum structural plates, a welded 4130 steel tube frame, and miscellaneous bearing holders and supports.

As viewed from the rear of the vehicle, all shafts and components connected to them spin CCW (counter clock wise).

A collar with in internal spline connects the main shaft driven by the engine to either a cogged belt drive that drives the propeller or a cogged belt that drives the continuously variable transmission (CVT). This collar is the means of transitioning between drive and flight modes, and, if transitioned correctly, only allows the car to be in one mode at any time, not both. The locking mechanism on this collar enables the user to verify this.

The propeller drive consists of a cogged belt and cogged pulleys configured so the propeller runs at a lower RPM than the engine. Additionally, the entire engine and support plates that bolt to it for the drive system are tilted relative to the vehicle chassis so that, in flight as the cart is normally nose up, the thrust line of the propeller is closer to being parallel with the relative wind and P-factor is reduced.

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The CVT has two sheaves that change in pitch diameter in response to RPM changes. The primary section is driven by a cogged belt drive. The secondary section is connected to the primary by a friction drive belt and drives the shaft entering the transaxle.

The transaxle is driven by the CVT and drives the rear axles. It has 3 modes: forward, reverse, and neutral, which are selected by the shifter in the cockpit.

See images in Appendix II.

3.2.2 Inspection:

3.2.2.1 All bolts must be secure and torqued to specification (if applicable). Inspect especially for major corrosion near steel bolts in contact with aluminum parts. No special tools or parts are required to accomplish this task. This line maintenance may be performed by owners through A&P.

3.2.2.2 All shafts should be centered and perpendicular to the support plates that their bearings or bearing holders are in. Total Indicated Runout (TIR) must be less than 0.0015” (0.04mm) on all shafts. A measuring device with sufficient resolution will be required. No parts are required to accomplish this task.

3.2.2.3 Visually inspect belts for frayed edges, tears, cracks, or delamination. Inspect for uneven wear on the belt (though a small degree of unevenness is usual), especially if one spot is worn more than others or if edges of a cogged belt are worn unevenly (which may indicate shaft or pulley misalignment). Contact manufacturer immediately for replacement or further inspection instructions if any defects are found. No special tools or parts are required to accomplish this task.

3.2.2.4 Inspect cogged pulleys and friction belt CVT pulleys. Sheaves should have smooth surfaces that show minimal wear and even wear. Foreign matter underneath belts (e.g. sand, dust, etc.) can rub on the sheaves and damage the surface the belts ride on. Guides should not be damaged in ways that will cause belt damage. No special tools or parts are required to accomplish this task.

3.2.2.5 Inspect bushings in pulleys and bushing tightening bolts. All bolts should be tight and torque stripe between shaft and bushing and bushing and pulley should indicate no relative motion between these parts. No special tools or parts are required to accomplish this task.

3.2.2.6 Check that the cog belts are properly tensioned. Use a belt tension meter and follow the guidelines in the tables below. Notify the manufacturer if belt tension is below these values by 10% or above by 5% for the propeller belt. The ground drive belt is not a safety of flight component, so if not attainable even used belt specs may be used for new belts. If a used belt is reinstalled, record the tension before removing and tension after re-installation must be the same. Additionally, if a used belt is reinstalled, it should travel in the same direction as it did before it was removed. No parts are required to accomplish this task. NOTE: Refer to ‘Maintenance and Repair’ section for any allowable maintenance to belts.

3.2.2.6.1 Propeller Cogged Belt Drive

Value New Belt Used Belt Rib/Strand Deflection Distance (in.) 0.27 0.27 Rib/Strand Deflection Force (lb) 55 - 60 41 - 46 Sonic Tension Meter, belt frequency (Hz) 125 - 131 106 - 113

Table 2. Propeller Cogged Belt Tension Values

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3.2.2.6.2 Ground Drive Cogged Belt Drive

Value New Belt Used Belt Rib/Strand Deflection Distance (in.) 0.12 0.12 Rib/Strand Deflection Force (lb) 42-52 30-40

Table 3. Ground Drive Cogged Belt Tension Values

3.2.3 Maintenance and Repair

3.2.3.1 Lubrication

3.2.3.1.1 Recommended Special Tools:

Grease gun with appropriate fittings

3.2.3.1.2 Required Parts

High quality, general purpose automotive bearing grease (see U-Joint manufacturer’s recommendations).

3.2.3.1.3 Type of Maintenance: Line

3.2.3.1.4 Level of Certification Required: Owner through A&P

3.2.3.1.5 Instructions: Grease U-Joints using installed grease fitting until full.

3.2.3.1.6 Test/Inspect: Confirm grease fitting is full.

3.2.3.2 All other maintenance: All maintenance shall be performed by Beyond Roads or a facility, entity, or individual they approve. Contact the manufacturer for a current list. Owners require no special tools, instructions, parts, or inspection procedures for these services.

3.3 Wing (Ram-Air Parachute)

3.3.1 Description: The Maverick ‘wing’ is a high-aspect ratio, elliptical, double canopy ram-air pressurized, rip-stop nylon parachute. The suspension and steering lines are made of a separate material as well. The parachute is connected to the aircraft by risers and working-load rated carabiners. All parachute maintenance should be handled by the manufacturer or a manufacturer approved facility.

See images in Appendix II.

3.3.2 Inspection:

3.3.2.1 Carabiners: Visually inspect the carabiners and threads for deep scratches, dents, or defects. Carabiner nuts should be secure. If not secure note this in a report and tighten finger tight plus ¼ turn with a wrench. Contact Beyond Roads for instructions before removing parachute for recertification or maintenance. No special tools or parts are required to accomplish this task.

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3.3.2.2 Risers: Inspect the risers for integrity of coating, frayed stitching or fabric, stress marks on fabric or stitching, and any other deterioration or degradation. No special tools or parts are required to accomplish this task.

3.3.2.3 Parachute: Layout the parachute flat on the ground behind the vehicle with the top surface of the canopy facing the ground and the bottom surface facing up. Inspect the bottom surface of the chute for any tears, holes, loose or frayed stitching, or discoloration (from contaminants or UV degradation). Turn the canopy over and repeat for the upper surface. Also inspect the ribs of the parachute, line loops, and crossports for damage, tearing, fraying, and loose or frayed stitching. Also verify that there is no major debris inside the cells of the chute. No special tools or parts are required to accomplish this task.

3.3.2.4 Parachute Lines: CAUTION: stepping on parachute lines and introducing dirt or sand into them can severely degrade strength and lead to premature failure. Avoid stepping on or pinching parachute lines. Shake the lines out and visually verify that the left and right sides are symmetrical, that the A and B lines go to the same carabiner on either side, that the C and D lines go to the same carabiner on either side, and that the lines go from their respective carabiners to the canopy without being twisted or knotted. Usually, if correctly rigged and installed, most apparent knots or twists can be remedied by simply shaking the lines out or by rotating individual carabiners relative to the chute). Verify that there are no loose, frayed, or torn lines (i.e. that all lines are connected at both ends to one of the following: the parachute, the carabiners, other lines, or the steering system). No special tools or parts are required to accomplish this task.

3.3.2.5 Steering Lines: Steering lines should be routed as shown in the illustrations and should not be routed so that during normal travel they rub on sharp corners or surfaces that would damage the lines. Inspect for fraying or other signs of wear and degradation. No special tools or parts are required to accomplish this task.

3.3.3 Maintenance and Repair:

Except as specified, only the manufacturer or manufacturer approved facility, entity, or individual may perform maintenance and repair of a Maverick parachute. Contact the manufacturer for more information.

3.3.3.1 General Care

3.3.3.1.1 Recommended Special Tools: soft cloths for cleaning

3.3.3.1.2 Required Parts: none

3.3.3.1.3 Type of Maintenance: Line

3.3.3.1.4 Level of Certification Required: Owner through A&P

3.3.3.1.5 Instructions:

3.3.3.1.5.1 If the chute is exposed to moisture and could remain damp or wet if stowed conventionally on the Maverick, at soonest convenience lay out or hang the parachute in a clean, dry, shaded location and allow the parachute to completely dry.

3.3.3.1.5.2 If dirt, mud, or organic debri (e.g. bugs and bird feces) soil the parachute, use very mild soapy water and a soft cloth to dab/wipe the affected areas clean. Dab/wipe dry with a clean cloth and allow to dry as above before stowing.

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3.3.3.1.6 Test/Inspect: Examine chute for cleanliness and dryness.

3.4 Control Systems

3.4.1 Description: The control system includes the steering, brake, throttle, and shifting systems. See images in Appendix II

3.4.1.1 Steering: The steering wheel is connected to the rack and pinion through the steering column. The electric fly-by-wire system has a sensor attached to the rack and pinion that provides input to the steering circuit board which controls the linear actuator electric steering motors. The steering wheel steers the front wheels on the ground and, with fly mode activated in flight, will activate the steering motors to pull on the parachute steering lines in order to steer the craft like a conventional PPC. The steering pedals function like those on a conventional PPC aircraft for steering (or back up if the electric system fails) and are required in normal operation for landing flare. The steering lines are routed through pulleys from the trim lock devices to the parachute.

3.4.1.2 Brakes: Each wheel has a disk brake, which is activated by the adjustable-position brake pedal through a master cylinder, proportioning valve, and brake lines. A parking brake (NOT EMERGENCY BRAKE) is implemented by a valve that, if shut after applying braking pressure, maintains braking pressure on the rear brakes after the brake pedal is released. Pressure is released by opening the valve. CAUTION: If there is no pressure in the system when the valve is closed, the parking brake will not be applied. Also, if the valve is closed and no pressure was in the system only the front brakes will activate if the brake pedal is pressed. Be sure to keep the valve open for normal driving and flying operation.

3.4.1.3 Throttle: The throttle is controlled by the adjustable-position gas pedal and/or a friction lever (primarily for in flight use). CAUTION: These controls operate in parallel, so releasing throttle on one will not decrease throttle held by the other and applying brakes will not decrease the throttle setting.

3.4.2 Inspection:

3.4.2.1 General: Check that all bolts and connectors are secure, that all moving parts have free and full range of motion (especially pulleys), and that no lines are frayed or damaged. All castle nuts must have cotter pins installed correctly. No special tools or parts are required to accomplish this task.

3.4.2.2 Steering: Check for full and interference free range of motion of the front wheels and electric steering cylinders. Check for excess movement in rack and pinion - there should be less than 1” of travel on the rim of the steering wheel before the wheels move or, when in flight mode, before the steering cylinders move in response to the steering wheel. Check for full articulation, smooth operation, and proper functionality of the manual steering pedals. Check that the trim locks work correctly and grasp the steering lines. Check that wires for the electric system are no frayed and connectors are secure. No special tools or parts are required to accomplish this task.

3.4.2.3 Brakes: Check brake pads for excessive wear and braking system for functionality. Check brake fluid level and system for leaks. Check parking break for correct functionality. No special tools or parts are required to accomplish this task.

3.4.3 Maintenance and Repair:

3.4.3.1 Bleeding Brakes

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3.4.3.1.1 Recommended Special Tools:

3.4.3.1.1.1 Collection device for excess brake fluid.

3.4.3.1.2 Required Parts: Approved brake fluid

3.4.3.1.3 Type of Maintenance: Line

3.4.3.1.4 Level of Certification Required: Owner through A&P

3.4.3.1.5 Instructions: Follow industry accepted practices.

3.4.3.1.6 Test/Inspection: Follow industry accepted practices.

4 ENGINE 4.0 Description: The engine is a Subaru MAV 4 cylinder, horizontally opposed, single overhead cam

engine. See “GENERAL” section for more information and specification. The coolant routing is modified so that the hoses that normally connect to a vehicle heater core simply connect to each other because no heater core is present, but the majority of the engine is very similar to a stock Subaru engine.

See Appendix II for illustrations.

4.1 Maintenance, Repair, and Overhaul: Except for routine engine maintenance as described below or as allowed for individuals with the certifications listed in the “Level of Certification Required to Perform Maintenance” section of this manual, all maintenance, repairs, and overhaul of the engine must be performed by the Beyond Roads or one of its authorized repair facilities or personnel. For a list of these facilities, contact the manufacturer.

4.1.1 Changing Oil and Filter

4.1.1.1 Recommended Special Tools:

4.1.1.1.1 drain plug wrench (if applicable)

4.1.1.1.2 oil filter wrench

4.1.1.2 Required Parts:

4.1.1.2.1 Oil: See “Approved Oils and Capacities” section.

4.1.1.2.2 Filter: See “Disposable Replacement Parts” section.

4.1.1.3 Type of Maintenance: Line

4.1.1.4 Certification Required: Owner through A&P

4.1.1.5 Procedure:

4.1.1.5.1 Warm up the engine by letting the it idle for 10 minutes to ease draining of the engine oil.

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4.1.1.5.2 Park aircraft on a level surface and stop the engine. Remove the oil filler cap.

4.1.1.5.3 Drain out the engine oil by removing the drain plug or opening the quick drain valve (if equipped) while the engine is still warm. The used oil should be drained into an appropriate container and disposed of properly. CAUTION: Engine Oil may be very hot and could cause burns.

4.1.1.5.4 If equipped with a quick drain plug, wipe the seating surface of the drain plug with a clean cloth and tighten it securely with a new sealing washer after the oil has completely drained out. If equipped with a quick drain, check that no oil leaks after closing the valve.

4.1.1.5.5 Remove the oil filter with an oil filter wrench.

4.1.1.5.6 Before installing a new oil filter, apply a thin coat of engine oil to the seal.

4.1.1.5.7 Clean the rubber seating area of the bottom of the engine and install the oil filter by hand tuning. Be careful not to twist or damage the seal.

4.1.1.5.8 Tighten the oil filter by hand until the rubber seal contacts the mating surface. Then tighten an additional half to three quarters of a turn.

4.1.1.5.9 Pour new engine oil through the filler neck.

4.1.1.5.10 Add the amount specified or until reaching fill line on dipstick.

4.1.1.5.11 Start the engine and make sure that no oil leaks appear around rubber oil filter seal and drain plug or quick drain valve.

4.1.1.5.12 Let engine cool and recheck oil level and add oil as necessary.

4.1.2 Adding Coolant

4.1.2.1 Recommended Special Tools: None

4.1.2.2 Required parts: Engine Coolant (Subaru Part Number: SOA868V9270, or equivalent approved by Subaru for engines specifying this part number)

4.1.2.3 Type of maintenance: Line

4.1.2.4 Certification Required: Owner/operator or above

4.1.2.5 Instructions:

4.1.2.5.1 Read warnings on Subaru Part Number: SOA868V9270, but do not drain and flush the coolant system.

4.1.2.5.2 Remove reservoir cap and fill to appropriate line as marked on the coolant reservoir.

4.1.2.5.3 Replace cap.

4.1.2.5.4 To drain and flush the coolant system, contact Beyond Roads.

4.1.2.6 Test/Inspect: Run engine for 5 minutes and reexamine coolant levels.

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5 FUEL SYSTEM 5.0 Description: The fuel system is comprised of a single welded aluminum fuel tank (with a strainer

on the bottom of the tank and fuel level sensor), fuel lines and fittings, two fuel pumps, fuel pressure regulator, in-line fuel filter and a Subaru fuel injection system or carburetor.

See images in Appendix II for illustrations.

5.1 Inspection: Visually check fuel tanks, lines, fittings, and injectors for damage, dents, and leaks. Verify that the fuel level indicator reads full or nearly full with the tank full of gas and, periodically, drain the gas to verify that it reads empty with no fuel in the tank. If damage or defects are discovered DO NOT fly or drive and contact manufacturer. Periodically check fuel pressure with a fuel pressure gage attached to the fuel pressure regulator. Proper pressure will depend on the engine in the Maverick, so contact Beyond Roads for specific engine specifications. No special tools or parts are required to accomplish this task other than those listed.

5.2 Maintenance, Repair, and Overhaul:

Except as specified below, all overhaul and repair must be performed by Beyond Roads or their approved facilities or personnel.

5.2.1 Changing the Fuel Filter

5.2.1.1 Recommended Special Tools: None

5.2.1.2 Required Parts: New manufacturer recommended fuel filter or equivalent. See “Disposable Replacement Parts” section.

5.2.1.3 Type of Maintenance: Line

5.2.1.4 Level of Certification Required: Owner through A&P

5.2.1.5 Procedure:

5.2.1.5.1 Disconnect the negative terminal on the battery

5.2.1.5.2 Disconnect fittings on both sides of fuel filter

5.2.1.5.3 Replace old filter element with equivalent new filter element

5.2.1.5.4 Reconnect fittings and appropriate brackets

5.2.1.5.5 Reconnect the negative terminal on the battery

5.2.1.6 Test/Inspect: Ensure engine runs properly.

6 PROPELLER 6.0 Description: The propeller is comprised of five ground-adjustable pitch blades mounted in a

propeller hub which is in turn mounted to a splined adapter to connect to the propeller shaft.

See image(s) in Appendix II for illustrations.

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6.1 Inspection: Visually inspect attaching nut and cotter key for presence and security. DO NOT fly or drive if damaged or loose. Inspect blades for nicks, cracks, delamination, or other damage. If leading edge protection is installed, inspect for damage. Inspect pitch setting and pitch of blades compared to each other. Follow all propeller manufacturer’s inspection guidelines, including torque values for bolts. No special tools or parts are required to accomplish this task unless otherwise noted.

6.2 Maintenance and Repair: Refer to and follow the propeller manufacturer’s maintenance manual for any propeller maintenance not covered in this manual. No special tools or parts are required to accomplish this task unless otherwise noted. Type of maintenance and level of certification is controlled by the propeller manufacturer’s maintenance manual.

7 UTILITY SYSTEMS 7.0 Description:

7.0.1 Body: The Maverick has an (optional) fabric covering (“tuxedo”) that covers the main chassis and engine compartment, a semi-rigid hood, optional fenders (front and rear), a windshield, and optional sun visors. These are non-structural and not safety of flight components. A storage compartment or bag (usually part of the tuxedo) is also provided for storing the parachute.

7.0.2 Wing Deployment System: The mast and spar system hold the wing in a position that, only with relative wind, is flight-ready. The spar is attached to the mast and extends to form a semi-rigid support for the leading edge of the parachute. The mast has ropes internally and a mechanism that allows a user to raise the spar for flight and lower it in a controlled manner. These are not structural or safety of flight systems. ‘Line Control’ is also implemented to prevent lines from being caught in the propeller when the parachute is not inflated.

7.0.3 Ground Operation Utilities: Head lights, brake lights, turn signal lights, parking brake, and horn. These are not safety of flight components.

7.1 Inspection:

7.1.1 Body: The fabric covering should not show major fraying, tearing, degradation, or loose stitching or fasteners. Inspect materials and all attachment points to the vehicle of all body components to ensure that no part will come off in flight or interfere with safe operation of the aircraft. All bolts should be secure. No special tools or parts are required to accomplish this task.

7.1.2 Wing Deployment System: Inspect mast and spar components for cracking, delamination, nicks, or other damage, especially at joints and mounting points. Inspect the attachment of the parachute to the spar to ensure it is sound. Inspect all ropes for abrasion and fraying, as well as the attachment of the spar to the mast and all knots/joints. Inspect all mechanisms for functionality. No special tools or parts are required to accomplish this task.

7.1.3 Ground Operation Utilities: All utilities should function in response to their switches. No special tools or parts are required to accomplish this task.

7.2 Maintenance and Repair:

7.2.1 Body:

7.2.1.1 Tuxedo:

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7.2.1.1.1 Cleaning

7.2.1.1.1.1 Recommended Special Tools: Compressed air system with blow-off tool. Soft brush.

7.2.1.1.1.2 Required Parts: None

7.2.1.1.1.3 Type of Maintenance: Line

7.2.1.1.1.4 Level of Certification Required: Owner through A&P

7.2.1.1.1.5 Instructions: Use compressed air to blow off dirt from the fabric covering and for more major cleaning, may use mild soap and water with a soft brush.

7.2.1.1.1.6 Test/Inspect: Visually inspect.

7.2.1.1.2 Alteration (Heavy Maintenance): Owner through A&P may modify the tuxedo as long as:

7.2.1.1.2.1 Recommended Special Tools: Varies by operation

7.2.1.1.2.2 Required Parts: Varies by operation

7.2.1.1.2.3 Type of Maintenance: Heavy

7.2.1.1.2.4 Level of Certification Required: Owner through A&P

7.2.1.1.2.5 Instructions: Modification is allowed if:

7.2.1.1.2.5.1 It does not hinder the passengers from safe exit (specifically under emergency conditions).

7.2.1.1.2.5.2 The tuxedo kit is firmly secured to the frame, (preventing the tuxedo kit or internal items from falling off or out and damaging the Maverick, its propeller, or other persons or property).

7.2.1.1.2.5.3 The modification does not change, remove, conceal or make unusable the aircraft identification information or required placards and markings.

7.2.1.1.2.5.4 Performed with specific consent of the manufacturer or performed by the manufacturer or manufacturer approved facilities or personnel.

7.2.1.2 Windshield, hood, fenders, sun visors (line maintenance): Owner through A&P may use cleaning products approved for these surfaces to clean them.

7.2.2 Wing Deployment System: Avoid grit between mating surfaces of the mast or spar components as these can cause severe degradation. Use clean cloth and/or compressed air to clean grit from these surfaces. Contact manufacturer for all other maintenance and repairs.

7.2.3 Ground Operation Utilities: Except for re-establishing any loose or disconnected connections per the manufacturer’s wiring diagram, all maintenance and repair must be done by the manufacturer or a manufacturer approved facility or personnel. Owners require no special tools or parts for this service.

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8 INSTRUMENTS AND AVIONICS 8.0 Description: See “Approved Equipment List” and instrument manufacturers’ descriptions. The

Engine kill switch is the key switch – turning the key to the up/off position kills the engine. The EIS displays and monitors, through the ECU and its sensors (or independent sensors) fuel level, oil pressure, coolant temperature and engine RPM.

8.1 Inspection: Check that all instruments and avionics are functioning correctly according to manufacturer specifications using industry accepted practices or instrument manufacturers’ instructions. Verify that the fuel level indicator reads full or nearly full with the tank full of gas and, periodically, drain the gas to verify that it reads empty with no fuel in the tank. EIS should display values correctly, at a minimum fuel lever, oil pressure, coolant temperature and engine RPM. No special tools or parts are required to accomplish this task.

8.2 Maintenance, Repair, Replacement, and Installation: All service should be performed by the manufacturer or manufacturer of the instrument. If applicable, owner through may follow the instrument manufacturer’s guidelines for removal/reinstallation of previously installed instruments for servicing by Beyond Roads or the manufacturer of the instrument. All permanent removal or new installation of instruments/avionics must be approved by Beyond Roads. No special tools or parts are required to accomplish this task unless otherwise noted.

9 ELECTRICAL SYSTEMS 9.0 Description: The electrical system consists of a sealed nominal 12 Volt battery; alternator with

voltage regulator; all wiring for utility, engine, instrument, and avionics systems; all electric instruments and avionics; and the electric fly-by-wire steering motors and control board.

9.1 Schematic Diagram: See images in Appendix III.

9.2 Inspection: All wires should be held securely and protected from chafing and pinching. All wire terminal connections and splices should be sound. All connectors should be intact and functional and wires held securely to them. Wires should have sufficient strain relief and be protected from extreme heat. No special tools or parts are required to accomplish this task.

9.3 Maintenance, Repair, and Alteration: All service should be performed by the manufacturer. As such, owners require no special tools or parts for this service.

10 STRUCTURAL REPAIRS 10.0 Maintenance, Repair, and Alteration: All services MUST be performed by the manufacturer

or manufacturer approved facility or personnel. As such, owners require no special tools or parts for this service.

11 PAINTING AND COATINGS 11.0 Description: The frame and suspension members are powder coated, as well as various

other pieces (mostly steel). The radiator shroud has an insulating coating. Some drive system parts are anodized. The hood and fenders may be painted (optional). The floor may have a covering for grip in some places. The exhaust system may have a high temperature coating.

11.1 Inspection: All coatings should completely cover the surfaces they are on and not be worn to the bare surface. The frame coating and coating on steel parts are especially critical for corrosion

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protection. All adhesive coatings need to be secure and still adhere to the surface they are on. No special tools or parts are required to accomplish this task.

11.2 Repair, Replacement, or Alteration:

11.2.1 Powder Coat and Paint: Owner through A&P may use durable touch up paint to recoat small damaged sections of any painted or powder coated part following industry accepted practice. More extensive painting may be done with specific manufacturer approval as long as required markings and placards are not concealed or marred.

11.2.2 All Other Coatings or for Major Service: Contact the manufacturer

12 REVISIONS TO MAINTENANCE MANUAL

(See Section I Revision Table and Appendix I)

13 FEEDBACK FORM Please report service difficulty, component malfunction/failure, and safety concerns found during maintenance or operation, including issues and anomalies in the maintenance manual, to Beyond Roads. They will be recorded and evaluated and may be acted upon for the continued airworthiness of the Maverick.

The following page includes the minimum information that an owner or maintainer must send to Beyond Roads to report service difficulties and/or possible safety of flight issues. Please visit www.Mavericklsa.com for a current version of this Feedback Form and follow the included instructions for sending it to Beyond Roads.

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Service Difficulty and Feedback Reporting Form Mail to Beyond Roads at: 10575 SW 147th Circle Dunnellon, FL 34432 Or E-mail to troy@Mavericklsa.com Or Fax to 815-377-3694 Name of reporting party _______________________________________ Date reported _______________ Date of event if any ________________ Make _________________ Model __________________ S/N_________ Address of reporting party _____________________________________ City, state, zip _______________________________________ Phone number __________________________________ Alt Phone _______________________________________ Email _______________________________________ Name of owner, if different ______________________________________ Address of owner ____________________________________________ City, state, zip _______________________________________ Phone number ______________________________________ Alt Phone _______________________________________ Email __________________________________________ Circumstances: (e.g. Hard landing, gust front, etc.) _____________________ __________________________________________________________________________________________________________________________________________________________________________________________ Component or system at fault: _____________________________________ ______________________________________________________________ FAA/NTSB contact if any (incl. date): ________________________________ ______________________________________________________________ Beyond Roads use only contacted __________________________________ Initial working issue ____________________________________________ Closure if any ______________________________________________ Closing date ________________________ Person __________________ Record number _______

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14 SAFETY DIRECTIVES 14.0 General: An SLSA may have a safety directive issued against it or a component part. Beyond

Roads will issue the directive as outlined in the applicable ASTM continued airworthiness specification. Beyond Roads will publish these safety directives on its web site and notify owners who properly maintain valid contact information with the Beyond Roads. Failure by the aircraft owner to maintain a proper address with Beyond Roads will void the aircraft’s airworthiness, until corrected.

14.1 Requirement for Compliance: For SLSA, service and safety directives are considered as mandatory tasks in order to maintain a condition of safe operation and compliance with the applicable original manufacturer’s ASTM design specification. A notice of such directives will also be issued to ELSA owners, but compliance will not be considered mandatory for continued airworthiness.

14.2 Instructions: Beyond Roads will supply the applicable instructions to comply with any safety directive, which will include:

14.2.1 A list of the tools needed to accomplish the task,

14.2.2 A list of the parts needed to perform the task,

14.2.3 Type of maintenance (for example, line, heavy, overhaul),

14.2.4 The level of certification needed to accomplish the task (for example, A&P, repairman inspection, etc.),

14.2.5 Detailed instructions and diagrams as needed to perform the task, and

14.2.6 Method to test/inspect to verify the task was accomplished properly.

14.3 Safety directives are considered as mandatory tasks in order to maintain a condition of safe operation and compliance with the applicable original ASTM design specification.

14.4 List of current safety directives, if any:

None, as of Sept 1, 2011

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15 ORIGINAL AND BACKUP DOCUMENT LOCATION: All originals of this and any other Maverick documents are kept at: 10575 SW 147th Circle Dunnellon, FL 34432 USA Backup copies of this and any other Maverick documents are kept at: 21235 SW 102nd St Rd Dunnellon, FL 34431 USA

To gain access to this data contact Troy Townsend at troy@Mavericklsa.com

Appendix I Change History Information: See Section I Revision Table.

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Appendix II NOTE: Images are typical and actual appearance may vary based on options selected and stock available. Structure – Acceptable Jack Location

Figure 1. Acceptable Jack Point, rear

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Suspension System

Figure 4: Rear Suspension and Tire Figure 5: Front Tire

Figure 2: Rear Suspension and Tire (rear view) Figure 3: Front Suspension

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Drive System, Transaxle

Figure 6: Transaxle

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Drive System

Figure 8: Drive Train

Figure 7: Ground Drive Axle

Figure 9: Ground Drive Continuously Variable Transmission

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Wing

Figure 10: Parachute Bottom View

Figure 12: Parachute Front View

Figure 11: Parachute Side View

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Control System

Figure 15: Brake and Accelerator Pedals

Figure 13: Steering Wheel

Figure 14: Rack and Pinion Assembly

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Figure 16: Manual Override Pedals, Linear Stepper Motors, Wiring Connectors, Rigging

Figure 17: Steering Input Sensor Located on Rack and Pinion

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Fuel System

Figure 18. Fuel Tank, Strainer, and Outlet

Figure 20. Fuel System Schematic Figure 19: Fuel Tank, In-Line Pumps, Fuel Filter

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Engine

Figure 21: Subaru MAV EJ22 Engine

Figure 22. Subaru MAV EJ25 Engine

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Propeller

Figure 23: Propeller

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Appendix III Maverick Wiring Diagram (with ECU 2 - AEM)

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Table 4: Maverick Wiring Diagram/Table (With ECU 1) – Also applies for fly by wire steering system

Not

e

Not

e

Spl

iced

with

2 w

ires,

1 fo

r le

ft &

1 fo

r pla

te

Spl

iced

with

cap

acito

r to

grou

nd (.

5 to

1 u

F @

250

V+)

Pin

tow

ards

rear

of e

ngin

e w

hen

inst

alle

d

Pin Pin C

B

A

D

Con

n.

Con

n.

Coi

l

Coi

l

Coi

l

Coi

l

Term

inal

Term

inal

Yel

5/1

6" R

ing

Red

3/1

6" R

ing

Red

#6

Rin

g

Red

#6

Rin

g

Red

Fem

ale

Spa

de

Red

But

t Spl

ice

Red

But

t Spl

ice

Red

But

t Spl

ice

But

t Spl

ice

In C

onne

ctor

But

t Spl

ice

But

t Spl

ice

In C

onne

ctor

To

To

Mas

ter

Sol

enoi

d

Mas

ter

Sol

enoi

d

Fuel

Pum

p #1

Fuel

Pum

p #2

Sta

rter

Rig

ht T

ail L

ight

Rig

ht B

rake

Li

ght

Left

Bra

ke L

ight

Igni

tion

Coi

l

Igni

tion

Coi

l

Igni

tion

Coi

l

Igni

tion

Coi

l

Inje

ctor

1

Sig

nal

Pin Pin 15

11

3

Con

n.

Con

n.

Dsu

b 15

M

ale

Dsu

b 15

M

ale

Dsu

b 15

M

ale

Term

inal

Term

inal

Yel

3/1

6" R

ing

Red

#6

Rin

g

Red

#6

Rin

g

Red

#6

Rin

g

Red

#8

Rin

g

Red

#6

Rin

g

Red

Fem

ale

Spa

de

Red

Fem

ale

Spa

de

Blu

e #8

Rin

g

Red

1/4

" Rin

g

Mal

e D

-Sub

Mal

e D

-Sub

Mal

e D

-Sub

From

From

Pan

el -

Fuse

Blo

ck

Pan

el -

Mas

ter S

w

Pan

el -

Fuel

Pum

p S

w

Pan

el -

Fuel

Pum

p S

w

Pan

el -

Key

Sw

itch

- S

tart

Pan

el -

Hea

dlig

ht S

w

Pan

el -

Rig

ht

Flas

her R

elay

Pan

el -

Left

Flas

her

Rel

ay

Pan

el -

Key

Sw

itch

- Ig

n

Gro

und

on E

ngin

e

EC

U -

EC

3 J1

EC

U -

EC

3 J1

EC

U -

EC

3 J1

- S

plic

ed to

EM

S

Rou

te

Rou

te

A-Y

A-Y

A-P

A-P

A-L

-N

A-L

-M

A-L

-M

A-L

-N

A-W

-E

xtra

P-W

-E

xtra

P-W

-E

xtra

P-W

Col

or

Col

or

Wh

Bk

Rd

Rd

Rd

Rd

Rd

Rd

Rd

Yel

/ W

h

Wire

Wire

12A

WG

18A

WG

16A

WG

16A

WG

18A

WG

18A

WG

18A

WG

18A

WG

18A

WG

18A

WG

20A

WG

20A

WG

Mav

eric

k M

ain

Wiri

ng H

arne

ss

Purp

ose

Purp

ose

Bus

Pow

er

Mas

ter S

w

Fuel

Pum

p #1

Fuel

Pum

p #2

Sta

rter

Tail

Ligh

ts

Rig

ht

Blin

ker/B

rake

Left

Blin

ker/B

rake

Igni

tion

Coi

l -

Pow

er

Igni

tion

Coi

l -

Gnd

Igni

tion

Coi

l - A

Igni

tion

Coi

l - D

Inje

ctor

1

Maintenance Manual

Date: Document #: 10-23-2012 500501

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# # 1 2 3 4 5 6 7 8 9 10

11

12

13

Not

e

Pin

tow

ards

rear

of e

ngin

e w

hen

inst

alle

d

Pin

tow

ards

fron

t of e

ngin

e w

hen

inst

alle

d

Pin

tow

ards

fron

t of e

ngin

e w

hen

inst

alle

d

1 w

ire fr

om e

ach

inje

ctor

into

B

utt S

plic

e at

V to

Fus

e B

lock

Not

e - 1

5-P

in F

emal

e D

sub

is a

t A a

nd 2

5-P

in M

ale

is a

t P

Not

e - 1

5-P

in F

emal

e D

sub

is a

t A a

nd 2

5-P

in M

ale

is a

t P

Not

e - 1

5-P

in F

emal

e D

sub

is a

t A a

nd 2

5-P

in M

ale

is a

t P

Not

e - 1

5-P

in F

emal

e D

sub

is a

t A a

nd 2

5-P

in M

ale

is a

t P

Not

e - 1

5-P

in F

emal

e D

sub

is a

t A a

nd 2

5-P

in M

ale

is a

t P

Not

e - 1

5-P

in F

emal

e D

sub

is a

t A a

nd 2

5-P

in M

ale

is a

t P

Not

e - 1

5-P

in F

emal

e D

sub

is a

t A a

nd 2

5-P

in M

ale

is a

t P

Pin

1 2 3 4 5 7 9

Con

n.

Dsu

b 15

Fe

mal

e

Dsu

b 15

Fe

mal

e

Dsu

b 15

Fe

mal

e

Dsu

b 15

Fe

mal

e

Dsu

b 15

Fe

mal

e

Dsu

b 15

Fe

mal

e

Dsu

b 15

Fe

mal

e

Term

inal

In C

onne

ctor

In C

onne

ctor

In C

onne

ctor

But

t Spl

ices

Fem

ale

D-S

ub

Fem

ale

D-S

ub

Fem

ale

D-S

ub

Fem

ale

D-S

ub

Fem

ale

D-S

ub

Fem

ale

D-S

ub

Fem

ale

D-S

ub

To

Inje

ctor

3

Sig

nal

Inje

ctor

2

Sig

nal

Inje

ctor

4

Sig

nal

4 In

ject

ors

- P

ower

EC

U

Pro

gram

mer

/Co

ntro

l

EC

U

Pro

gram

mer

/Co

ntro

l

EC

U

Pro

gram

mer

/Co

ntro

l

EC

U

Pro

gram

mer

/Co

ntro

l

EC

U

Pro

gram

mer

/Co

ntro

l

EC

U

Pro

gram

mer

/Co

ntro

l

EC

U

Pro

gram

mer

/Co

ntro

l

Pin

5 4 6 14

9 10

24

8 2 4

Con

n.

Dsu

b 15

M

ale

Dsu

b 15

M

ale

Dsu

b 15

M

ale

Dsu

b 25

M

ale

Dsu

b 25

M

ale

Dsu

b 25

M

ale

Dsu

b 25

M

ale

Dsu

b 25

M

ale

Dsu

b 25

M

ale

Dsu

b 25

M

ale

Term

inal

Mal

e D

-Sub

Mal

e D

-Sub

Mal

e D

-Sub

Red

Fem

ale

Spa

de

Mal

e D

-Sub

Mal

e D

-Sub

Mal

e D

-Sub

Mal

e D

-Sub

Mal

e D

-Sub

Mal

e D

-Sub

Mal

e D

-Sub

From

EC

U -

EC

3 J1

EC

U -

EC

3 J1

EC

U -

EC

3 J1

Rea

r Fus

e B

lock

EC

U -

EC

3 J2

EC

U -

EC

3 J2

EC

U -

EC

3 J2

EC

U -

EC

3 J2

EC

U -

EC

3 J2

EC

U -

EC

3 J2

EC

U -

EC

3 J2

Rou

te

P-W

-E

xtra

6

P-R

P-R

-E

xtra

6

2R-P

-v-

2W-X

P-A

P-A

P-A

P-A

P-A

P-A

P-A

Col

or

Rd

Wh

Bl

Or

Gr

Wh

Bl

Or

Wire

18A

WG

22A

WG

S-4

C-1

22A

WG

S-4

C-2

Purp

ose

Inje

ctor

3

Inje

ctor

2

Inje

ctor

4

Inje

ctor

Pow

er

EC

U C

ontro

ller

EC

U C

ontro

ller

EC

U C

ontro

ller

EC

U C

ontro

ller

EC

U C

ontro

ller

EC

U C

ontro

ller

EC

U C

ontro

ller

Mav

eric

k M

ain

Wiri

ng H

arne

ss

# 14

15

16

17

18

19

20

21

22

23

24

Maintenance Manual

Date: Document #: 10-23-2012 500501

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Not

e

Not

e - 1

5-P

in F

emal

e D

sub

is a

t A a

nd 2

5-P

in M

ale

is a

t P

Not

e - 1

5-P

in F

emal

e D

sub

is a

t A a

nd 2

5-P

in M

ale

is a

t P

Not

e - 1

5-P

in F

emal

e D

sub

is a

t A a

nd 2

5-P

in M

ale

is a

t P

Not

e - 1

5-P

in F

emal

e D

sub

is a

t A a

nd 2

5-P

in M

ale

is a

t P

On

bolt

side

of c

rank

sen

sor

On

bolt

side

of c

rank

sen

sor

Spl

ice

both

into

1 w

ith

exte

nsio

n fo

r D-S

ub P

in

Spl

ice

with

Cra

nk/C

am

Shi

elds

& G

roun

d w

ith M

ass

Gro

und

Pin

10

11

13

15

10

4

Con

n.

Dsu

b 15

Fe

mal

e

Dsu

b 15

Fe

mal

e

Dsu

b 15

Fe

mal

e

Dsu

b 15

Fe

mal

e

TB4

TB4

Term

inal

Fem

ale

D-S

ub

Fem

ale

D-S

ub

Fem

ale

D-S

ub

Fem

ale

D-S

ub

Red

Fem

ale

Spa

de

Red

Fem

ale

Spa

de

In C

onne

ctor

In C

onne

ctor

In C

onne

ctor

s

Red

Fem

ale

Spa

de

Red

Mal

e S

pade

Bar

e W

ire

Bar

e W

ire

To

EC

U

Pro

gram

mer

/ C

ontro

l

EC

U

Pro

gram

mer

/ C

ontro

l

EC

U

Pro

gram

mer

/ C

ontro

l

EC

U

Pro

gram

mer

/ C

ontro

l

Rea

r Fus

e B

lock

Rea

r Fus

e B

lock

Cra

nk S

enso

r

Cam

Sen

sor

Cra

nk &

Cam

S

enso

r

Left

Rea

r of

Eng

ine

Left

Rea

r of

Eng

ine

EM

S A

QM

EM

S A

QM

Pin

22

23

7 25

20

19

5 6 15

17

12

13

Con

n.

Dsu

b 25

M

ale

Dsu

b 25

M

ale

Dsu

b 25

M

ale

Dsu

b 25

M

ale

Dsu

b 25

M

ale

Dsu

b 25

M

ale

Dsu

b 25

M

ale

Dsu

b 25

M

ale

Dsu

b 25

M

ale

Dsu

b 25

M

ale

Dsu

b 25

M

ale

Dsu

b 25

M

ale

Term

inal

Mal

e D

-Sub

Mal

e D

-Sub

Mal

e D

-Sub

Mal

e D

-Sub

Mal

e D

-Sub

Mal

e D

-Sub

Mal

e D

-Sub

Mal

e D

-Sub

Mal

e D

-Sub

Mal

e D

-Sub

Yel

low

But

t S

plic

e

Mal

e D

-Sub

Mal

e D

-Sub

From

EC

U -

EC

3 J2

EC

U -

EC

3 J2

EC

U -

EC

3 J2

EC

U -

EC

3 J2

EC

U -

EC

3 J2

EC

U -

EC

3 J2

EC

U -

EC

3 J2

EC

U -

EC

3 J2

EC

U -

EC

3 J2

EC

U -

EC

3 J2

Gro

und

Stu

d on

E

CU

Cas

e

EC

U -

EC

3 J2

EC

U -

EC

3 J2

Rou

te

P-A

P-A

P-A

P-A

P-V

-X

P-V

-X

P-S

P-S

P-S

P-R

-U

P-R

-U

P-P

P-P

Col

or

Gr

Wh

Bl

Or

Wh

Bl

Yel

Bk

Wh

Bl

Wire

22A

WG

S-3

C

20A

WG

S-2

C

20A

WG

20A

WG

20A

WG

S-2

C

Purp

ose

EC

U C

ontro

ller

EC

U C

ontro

ller

EC

U C

ontro

ller

EC

U C

ontro

ller

EC

U P

ower

EC

U P

ower

Cra

nk S

enso

r +

Cam

Sen

sor +

Cra

nk/C

am -

Inle

t Air

Tem

p + In

let A

ir Te

mp

-

EC

U-E

MS

S

eria

l

EC

U-E

MS

S

eria

l

Mav

eric

k M

ain

Wiri

ng H

arne

ss

# 25

26

27

28

29

30

31

32

33

34

35

36

37

Maintenance Manual

Date: Document #: 10-23-2012 500501

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Not

e

Spl

ice

in w

ith M

ass

Gro

und

Leav

e 9-

Pin

han

ging

for

prog

ram

min

g

Leav

e 9-

Pin

han

ging

for

prog

ram

min

g

Leav

e 9-

Pin

han

ging

for

prog

ram

min

g

(|--d

iode

) Gro

uped

at A

(--|d

iode

) Gro

uped

at A

Gro

uped

at A

- N

ote

Pin

#

Gro

uped

at A

- N

ote

Pin

#

Pin

12

13

14

15

3 8 9 7 2 3 5 1 2 3

Con

n.

TB4

TB4

TB4

TB4

TB4

TB4

TB4

TB4

Dsu

b 9

Fem

ale

Dsu

b 9

Fem

ale

Dsu

b 9

Fem

ale

CP

C 4

Sam

e as

A

bove

CP

C 4

CP

C 4

Term

inal

Bar

e W

ire

Bar

e W

ire

Bar

e W

ire

Bar

e W

ire

Bar

e W

ire

Bar

e W

ire

Bar

e W

ire

Bar

e W

ire

Fem

ale

D-S

ub

Fem

ale

D-S

ub

Fem

ale

D-S

ub

CP

C F

emal

e

CP

C F

emal

e

CP

C F

emal

e

CP

C F

emal

e

To

EM

S A

QM

EM

S A

QM

EM

S A

QM

EM

S A

QM

EM

S A

QM

EM

S A

QM

EM

S A

QM

EM

S A

QM

Pro

gram

min

g C

onne

ctor

Ste

erin

g P

ot

CP

C

Ste

erin

g P

ot

CP

C

Ste

erin

g P

ot

CP

C

Ste

erin

g P

ot

CP

C

Pin

5 17

7 6 2 3 5 11

10

14

13

Con

n.

Dsu

b 25

M

ale

Dsu

b 25

M

ale

Dsu

b 25

M

ale

Dsu

b 25

M

ale

Dsu

b 15

M

ale

Dsu

b 15

M

ale

Dsu

b 15

M

ale

Dsu

b 15

M

ale

Dsu

b 15

M

ale

Dsu

b 15

M

ale

Dsu

b 15

M

ale

Term

inal

Mal

e D

-Sub

Mal

e D

-Sub

Mal

e D

-Sub

Mal

e D

-Sub

But

t Spl

ice

Red

Fem

ale

Spa

de

Red

5/1

6" R

ing

Yel

low

But

t S

plic

e

Mal

e D

-Sub

Mal

e D

-Sub

Mal

e D

-Sub

Mal

e D

-Sub

Mal

e D

-Sub

Mal

e D

-Sub

Mal

e D

-Sub

From

EM

S D

ispl

ay

EM

S D

ispl

ay

EM

S D

ispl

ay

EM

S D

ispl

ay

EC

U -

EC

3 J1

- S

plic

ed to

EM

S

Rea

r Fus

e B

lock

Mas

ter S

olen

oid

Gro

und

Stu

d on

E

CU

Cas

e

Ste

erin

g B

oard

- P

rogr

am

Ste

erin

g B

oard

- P

rogr

am

Ste

erin

g B

oard

- P

rogr

am

Ste

erin

g B

oard

- G

roup

ed

Ste

erin

g B

oard

- G

roup

ed

Ste

erin

g B

oard

- G

roup

ed

Ste

erin

g B

oard

- G

roup

ed

Rou

te

A-P

A-P

A-P

A-P

P-P

P-V

-X

P-V

-X

P-P

A

A

A

A-Z

A-Z

A-Z

A-Z

Col

or

Wh

Bl

Or

Gr

Yel

Rd

Yel

Bk

Wh

Or

Bl

Wh

Wh

Or

Bl

Wire

22A

WG

S-4

C

20A

WG

18A

WG

18A

WG

20A

WG

22A

WG

-3C

22A

WG

S-3

C

Purp

ose

EM

S A

QM

-D

ispl

ay

EM

S A

QM

-D

ispl

ay

EM

S A

QM

-D

ispl

ay

EM

S A

QM

-D

ispl

ay

EM

S A

QM

Ta

ch

EM

S A

QM

P

ower

EM

S A

QM

V

olta

ge

EM

S A

QM

G

roun

d

Ste

erin

g

Ste

erin

g

Ste

erin

g

Ste

erin

g

Ste

erin

g

Ste

erin

g

Ste

erin

g

Mav

eric

k M

ain

Wiri

ng H

arne

ss

# 38

39

40

41

42

43

44

45

46

47

48

49

50

51

52

Maintenance Manual

Date: Document #: 10-23-2012 500501

47 of 47

Not

e

Gro

uped

at A

- N

ote

Pin

#

(10K

Res

isto

r) G

roup

ed a

t A

- Not

e P

in #

Gro

uped

at A

- N

ote

Pin

#

(10K

Res

isto

r) G

roup

ed a

t A

- Not

e P

in #

Pin 1 2 3 1 2 3 4 5 5 4

Con

n.

CP

C 9

CP

C 9

CP

C 9

CP

C 9

CP

C 9

CP

C 9

CP

C 9

CP

C 9

CP

C 9

CP

C 9

Term

inal

CP

C F

emal

e

CP

C F

emal

e

CP

C F

emal

e

CP

C F

emal

e

CP

C F

emal

e

CP

C F

emal

e

CP

C F

emal

e

CP

C F

emal

e

CP

C F

emal

e

CP

C F

emal

e

To

Ste

erin

g C

ylin

der R

ight

Ste

erin

g C

ylin

der R

ight

Ste

erin

g C

ylin

der R

ight

Ste

erin

g C

ylin

der L

eft

Ste

erin

g C

ylin

der L

eft

Ste

erin

g C

ylin

der L

eft

Ste

erin

g C

ylin

der L

eft

Ste

erin

g C

ylin

der L

eft

Ste

erin

g C

ylin

der R

ight

Ste

erin

g C

ylin

der R

ight

Pin 8 13

14

12

14

13

M1+

M1-

M2+

M2-

Con

n.

Dsu

b 15

M

ale

Dsu

b 15

M

ale

Dsu

b 15

M

ale

Dsu

b 15

M

ale

Dsu

b 15

M

ale

Dsu

b 15

M

ale

Scr

ew L

ug

Scr

ew L

ug

Scr

ew L

ug

Scr

ew L

ug

Term

inal

Mal

e D

-Sub

Mal

e D

-Sub

Mal

e D

-Sub

Mal

e D

-Sub

Mal

e D

-Sub

Mal

e D

-Sub

Bar

e W

ire

Bar

e W

ire

Bar

e W

ire

Bar

e W

ire

From

Ste

erin

g B

oard

Ste

erin

g B

oard

- G

roup

ed

Ste

erin

g B

oard

- G

roup

ed

Ste

erin

g B

oard

Ste

erin

g B

oard

- G

roup

ed

Ste

erin

g B

oard

- G

roup

ed

Ste

erin

g B

oard

- M

otor

Sid

e

Ste

erin

g B

oard

- M

otor

Sid

e

Ste

erin

g B

oard

- M

otor

Sid

e

Ste

erin

g B

oard

- M

otor

Sid

e

Rou

te

Col

or

Wh

Or

Bl

Wh

Or

Bl

Rd

Rd

Rd

Rd

Wire

22A

WG

S-3

C

22A

WG

S-3

C

16A

WG

16A

WG

16A

WG

16A

WG

Purp

ose

Ste

erin

g

Ste

erin

g

Ste

erin

g

Ste

erin

g

Ste

erin

g

Ste

erin

g

Ste

erin

g

Ste

erin

g

Ste

erin

g

Ste

erin

g

Mav

eric

k M

ain

Wiri

ng H

arne

ss

# 53

54

55

56

57

58

59

60

61

62