Defect Reports

Click here to submit a Defect Report on-line

The following comprises of defects reported from members and manufacturers

March 2016

Glass Fuel Filter Failure

Airborne XT-912 (2005) TSN 680hrs.

Original Fuel Filter: Filter failure was found during an annual service, approx. 13 days after aircraft was last flown.

There appears to be fatigue of the alloy die cast core. Alloy break showed many air bubbles in the casting.

Airborne have been informed and we are awaiting feedback regarding their findings.

broken fitting   image002


Broken Wheel Spat Bracket

1). Airborne XT-912 (2005) TSN 680hrs.
2). Airborne XT-912 (2005) TSN 405.16hrs:

Pre-Flight Inspection: Give the wheel spats a gentle shake from side to side to check for any movement. If any movement is noticed, check this bracket for signs of cracking. File a defect report via the HGFA website or contact the HGFA WM Technical Manager or HGFA Operations Manager with details.

broken fitting   image002

Cracked RH Wing Adjuster Webbing Cap

Airborne XT-912 Tourer (2005) TSN 376hrs.:  Stress crack radiating from the securing screw (IPC Item 10, part # 105140) found during post flight inspection. Both LH and RH leading edge tensioner assemblies (part #s 104669 and 104740) were replaced with new style parts purchased and supplied by Airborne.  2 x test flights subsequently conducted to confirm wing tuning settings.


September 2015

Hinge Batten Fitting Security - Airborne Windsports Wings

Identification: SB-019 (Click to follow link)

Status: Active

Issue Date: 01-09-2015

Issued By: Rick Duncan

Applicability: All Airborne Windsports Wings

Compliance: 100 Hourly line maintenance

Reference: Material Airborne Engineering Report 15/025/DS

Hinge Batten Fitting Security SB-019


August 2015

Malibu bottom upright fitting wire wear issue

Applies from: 17th August, 2015

Applies to: Any Moyes glider using round uprights.

Inspection: Whenever an upright is broken or bent it may cause damage to the top and bottom upright fittings, these parts should be inspected closely and replaced at any sign of wear or damage.

Service Requirement: Replace bottom upright fitting after 300 hours or if wire slot widens to greater than 4.8 mm.

It has been bought to our attention of a potential problem of the bottom upright fitting on gliders with round uprights.
The wear has occurred on the slot where the ball swage fits into.

broken fitting

The photo shows a fitting from a glider with 600+ hours airtime where the slot has been worn and widened.


The photo shows a broken fitting from a training glider.

It is now mandatory to replace the fitting
when the opening exceeds 4.8mm or after 300 hours airtime.


January 2015

Defect Report #8: Airborne XT-582 - Part No. 106910 Bracket Intake Silencer XT582 Rear.

Aircraft Type: Airborne XT-582

Inspection recommended - Prior to next flight and subsequently after every flight.
The bracket needs to be thoroughly inspected for cracks.

Defect: Reports of cracking of the air intake silencer rear mounting bracket. Airborne have increase the length of the bracket as the original one was too short.

If cracking is found, please contact Airborne directly.

Resolved: Airborne have increased the length of the bracket.


Defect Report #7: Airborne XT-912 - Engine/oil cooler mount brackets.

Aircraft Type: Airborne XT-912B

Inspection recommended - Prior to next flight and subsequently after every flight.
The brackets needs to be thoroughly inspected for cracks.

Defect: Reports of cracking of the engine/cooler mounting brackets where the nut has been tightened onto a step in the bracket causing undue stress in that location.

If cracking is found, please file a WM Defect Report on the HGFA website.

Airborne have been made aware of this issue and are supplying replacement brackets.
The engine mount bolts torque value will be added to their next manual update.

Please be aware that when installing the new Engine Brackets, the following Torques need to be applied:

Top Link bolt (part number 105515):  6mm bolt. Torque 10Nm  

Engine mount bolts (part number: 105944) x 4:  10mm bolt.  Torque 50Nm, apply Loctite 243

For specific torques on oil cooler fittings and exhaust manifold refer to Rotax 912 Illustrated Parts Catalogue.

Reinstallation of exhaust components should be done iaw the Aircraft Maintenance Manual, taking care to tighten the manifold nuts evenly to ensure that no stress is put on the manifold, which could induce cracking


Defect Report #6: Airborne XT-912 - Plastic Fuel-cock handle.

Aircraft Type: Airborne XT-912 Rotax 80hp

Inspection recommended - Prior to next flight, carry out a functional check of the fuel cock as part of pre-flight inspection. Remove and inspect handle for rounding or cracking.

Defect: Fuel shut off valve handle was moved from off to on position and on engine start up the engine ran for 10 to 12 sec before it shut down. Inspection found the fuel shut off valve was in the "off" position whilst the handle showed the "on" position.

If rounding or cracking is found, please file a WM Defect Report on the HGFA website.

Airborne have been made aware of this issue and we await their response. We will publish findings/corrective action when received.



June 2009

582 Oil Filter Bracket Failure

Reports are being received regarding the Oil Filter Bracket on Airborne 582 aircraft. There does not seem to be any report of similar failures on any other model or make. Airborne have been made aware of this issue and we await their comment in response to the issue.


The upper half segment of the two stroke oil tank mounting bracket is noted to crack (see picture) . This fracture is in the 90 degree radius bend, adjacent to the three cylinder head bolts / isolator mounts that provide sole support for this assembly.

Rotax (Aust) say they aware that some of these oil tank brackets are breaking, some after only 50 hrs !

The recent reports which involve aircraft at 800 hrs and 300 hrs respectively, although still a concern,  would expect some type of wear at these hours in service. All reports involve the top bracket.

Rotax (Aust) note that it seems to point at some sort of harmonic vibration in this particular aircraft.

April 09
NZ CAA Notice Regarding findings on Airborne XTS 912 Microlight Materials

19 May 08

Reserve Deployment Issue for SupAir Altix & Evo X-C Harnesses

April 08
ROTAX Mandatory Service Bulletin

6 October 05

Mandatory Service Bulletin for Cruise and Streak 3 Trike Wing - Wing Knuckles


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