Service Manual Extra 300L

SERVICE MANUAL
EXTRA 300L
Doc. No: EA-06702
EXTRA
FLUGZEUGPRODUKTIONS-
UND VERTRIEBS-GMBH
Schwarze Heide 21
D-46569 Hünxe, Germany
Tel: 49-28 58-91 37-0
Fax: 49-28 58-91 37-30
EXTRA
SERVICE MANUAL EXTRA 300L
List of Effective Pages

Chapter Page Date of Issue Chapter Page Date of Issue Chapter Page Date of Issue
Cover sheet 15. December 2005 15 16. January 2009 6 1. June 1995
A 31. June 2009 16 16. January 2009 12 1 16. January 2009
B 4. June 2009 17 16. January 2009 2 16. January 2009
C 4. June 2009 18 16. January 2009 3 16. January 2009
D 31. June 2009 19 16. January 2009 4 16. January 2009
E 16. June 2008 20 16. January 2009 5 16. January 2009
F 16. June 2008 21 16. January 2009 6 16. January 2009
G 16. June 2008 22 16. January 2009 7 16. January 2009
H 16. June 2008 23 16. January 2009 8 16. January 2009
I 16. June 2008 24 16. January 2009 9 16. January 2009
01 1 1. June 1995 25 16. January 2009 10 16. January 2009
2 16. June 2008 26 16. January 2009 11 16. January 2009
3 16. June 2008 27 31. June 2009 12 16. January 2009
4 4. June 2009 28 31. June 2009 13 16. January 2009
02 1 1. June 1995 32 16. January 2009 17 16. January 2009
2 1. June 1995 33 16. January 2009 20 1 1. June 1995
3 1. June 1995 34 16. January 2009 2 1. June 1995
03 1 1. June 1995 40 16. January 2009 8 4. December 2001
2 1. June 1995 06 1 1. June 1995 9 1. June 1995
3 1. June 1995 2 1. June 1995 10 15. December 2005
5 16. January 2009 4 1. June 1995 12 1. June 1995
6 16. January 2009 5 16. January 2009 13 1. June 1995
04 1 31. January 1995 07 1 1. June 1995 23 1 1. June 1995
6 31. January 1995 08 1 1. June 1995 6 1. June 1995
05 1 16. January 2009 3 1. June 1995 24 1 1. June 1995
5 31. June 2009 7 1. June 1995 5 4. June 2009
12 16. January 2009 3 1. June 1995 25 1 1. June 1995
PAGE DATE:
DATE:1.
31.June
June1995
2009 PAGE A
EXTRA

4 15. December 1999 22 16. January 2009 30 deleted

5 1. June 1995 23 16. January 2009 31 deleted
27 1 1. June 1995 25 16. January 2009 33 deleted
4 16. January 2009 28 16. January 2009 36 deleted
10 1. June 1995 34 16. January 2009 33 1 1. June 1995
11 1. June 1995 31 1 1. June 1995 2 1. June 1995
12 1. June 1995 2 4. June 2009 3 1. June 1995
13 1. June 1995 3 1. June 1995 4 1. June 1995
14 1. June 1995 4 1. June 1997 5 1. June 1995
15 1. June 1995 5 1. June 1995 6 1. June 1995
16 1. June 1995 6 4. June 2009 7 1. June 1995
17 1. June 1996 7 4. June 2009 34 1 1. June 1995
19 1. June 1996 9 4. June 2009 3 1. June 1995
19A 1. June 1996 10 1. June 1997 4 1. June 1995
20 1. June 1996 32 1 1. June 1995 5 1. June 1995
21 1. June 1996 2 1. June 1996 6 1. June 1995
22 1. June 1996 3 1. June 1996 7 1. June 1995
23 1. June 1995 4 1. June 1996 8 1. June 1995
24 1. June 1995 5 1. June 1995 9 1. June 1995
26 1. June 1995 7 1. June 1996 51 1 1. June 1995
27 16. January 2009 8 15. December 1999 2 1. June 1997
28 16. January 2009 9 15. December 1999 3 16. January 2009
28 1 16. January 2009 9A 15. December 1999 4 1. June 1995
2 16. January 2009 10 1. June 1995 5 15. December 1999
5 16. January 2009 13 15. December 1999 8 1. June 1995
6 16. January 2009 14 deleted 9 1. June 1995
11 16. January 2009 19 deleted 13A 16. January 2009
15 16. January 2009 23 deleted 17 15. December 1999
PAGE
PAGE DATE:
DATE:1.
4.June
June1995
2009 PAGE B
EXTRA

24 1. June 1995 3 4. June 2009 5 4. June 2009

25 1. June 1995 4 4. June 2009 6 4. June 2009
26 1. June 1995 5 4. June 2009 7 4. June 2009
27 1. June 1995 6 4. June 2009 79 1 4. June 2009
28 1. June 1995 7 4. June 2009 2 4. June 2009
29 1. June 1995 8 4. June 2009 3 4. June 2009
30 1. June 1997 9 4. June 2009 4 4. June 2009
31 1. June 1995 71 1 4. June 2009 5 4. June 2009
32 1. June 1995 2 4. June 2009 6 4. June 2009
33 1. June 1995 3 4. June 2009 7 4. June 2009
34 1. June 1995 4 4. June 2009 8 4. June 2009
53 1 1. June 1995 5 4. June 2009 9 4. June 2009
3 1. June 1995 7 4. June 2009 11 4. June 2009
4 1. June 1995 8 4. June 2009 12 4. June 2009
5 1. June 1995 9 4. June 2009 13 4. June 2009
6 1. June 1995 10 4. June 2009 91 1 1. June 1995
7 1. June 1995 11 4. June 2009 2 1. June 1995
8 1. June 1995 72 1 4. June 2009 3 1. June 1995
9 1. June 1995 2 4. June 2009 4 1. June 1995
10 15. December 1999 3 4. June 2009 5 1. June 1995
55 1 1. June 1995 2 4. June 2009 12 1. June 1995
2 1. June 1995 3 4. June 2009 13 1. June 1995
3 1. June 1995 4 4. June 2009 14 1. June 1995
4 1. June 1995 5 4. June 2009 15 1. June 1995
5 1. June 1995 6 4. June 2009 16 1. June 1995
6 1. June 1995 7 4. June 2009 17 1. June 1995
7 1. June 1997 8 4. June 2009 95 1 1. June 1995
8 1. June 1997 9 4. June 2009 2 1. June 1995
9 1. June 1995 10 4. June 2009
10 1. June 1995 11 4. June 2009
11 1. June 1995 12 4. June 2009
57 1 1. June 1995 13 4. June 2009
2 1. June 1997 14 4. June 2009
3 1. June 1997 77 1 4. June 2009
4 15. December 1999 2 4. June 2009
5 15. December 1999 3 4. June 2009
6 15. December 1999 4 4. June 2009
7 4. June 2009 5 4. June 2009
8 1. June 1995 6 4. June 2009
9 1. June 1995 7 4. June 2009
10 1. June 1995 8 4. June 2009
11 1. June 1995 9 4. June 2009
12 1. June 1997 78 1 4. June 2009
13 1. June 1997 2 4. June 2009
61 1 4. June 2009 3 4. June 2009
2 4. June 2009 4 4. June 2009
PAGE
PAGEDATE:
DATE:1.
4.June
June1995
2009 PAGE C
EXTRA
Record of Revisions
Rev. Rev.
No. Issue Date Date inserted by No. Issue Date Date inserted by
1. Ed. 1. June 1995 1. June 1995 Extra

1 1. June 1996 1. June 1996 Extra
2 1. June 1997 1. June 1997 Extra
3 15. December 1999 15. December 1999 Extra
6 16. June 2008 16. June 2008 Extra
7 16. January 2009 16. January 2009 Extra
8 4. June 2009 4. June 2009 Extra
9 31. June 2009 31. June 2009 Extra
PAGE DATE:
DATE:1.
31.June
June1995
2009 PAGE D
EXTRA
List of Service Bulletins/Service Letters

Issue Serial N° German AD
S.B./S.L. N° Subject
Date affected (LTA)
SB-300-2-95 30.01.01 Upper Longeron Insp. 001 thr. 005 -
SB-300-3-95 12.05.98 Rudder pedal safety control stop 001 thr. 015 95-443
12, 14 thr. 20,

SB-300-2-97 25.09.97 Fuselage structure tail spring support 98-001
21 thr. 48
Securing the wire stirrup of the

SB-300-1-01 26.03.01 001 thr. 133 -
gascolator bowl
2002-408
SL-300-09-02 19.09.02 Fuel selector valve leakage all FAA: AD
2003-17-02
001 thru 167, 1168*

SB-300-1-04 25.03.04 Replacement Fuel Hose to Filler Cap
thru 1170,1172, 1173
Change Long Range Tanks- to 001 thr. 167, 1168*

SB-300-3-04 30.04.04
Standard Tanks Configuration thru 1170, 1172, 1173
D-2004-489;
01 thr. 167, 1168*
SB-300-4-04 25.05.04 Bottom fuselage cover/firewall sealing FAA: AD 2005-
thru 1181
11-07
01 thr. 167, 1168*
SB-300-1-05 27.07.05 Engine fuel pump vent thru 1199, 1201 thru
1203
A/C equipped with
the single oil cooler
SB-300-1-06 18.08.06 Repositioning of Single Oil Cooler
system manufactured
before May 2006
*) Serial numbers 1168 thru 1170 and 1172 thru 1173 are also named without the first digit (168, 169 etc.)
PAGE DATE: 1.
16.June 1995
June 2008 PAGE E
EXTRA
CONTENTS
Title Page
List of Effective Pages ........................................................................................................................................................... A-C

Record of Revisions .......................................................................................................................................................................D
List of Service Bulletins/Service Letters E
.....................................................................................................................
Contents ................................................................................................................................................................................................ F-G

Fax formats .......................................................................................................................................................................................... H-I
Group/Chapter title Chapter
GENERAL
Introduction .......................................................................................................................................................................................... 01
How to Use the Service Manual ......................................................................................................................................... 02
AIRCRAFT
General Description ...................................................................................................................................................................... 03

Airworthiness Limitations ....................................................................................................................................................... 04
Time Limits/Maintenance Checks ................................................................................................................................... 05
Dimensions and Areas ................................................................................................................................................................. 06
Lifting and Shoring ......................................................................................................................................................................... 07
Levelling and Weighing .............................................................................................................................................................. 08
Towing and Taxiing .......................................................................................................................................................................... 09
Parking, Mooring, Storage and Return to Service .............................................................................................. 10
Servicing .................................................................................................................................................................................................. 12
AIRFRAME SYSTEMS
Standard Practices - Airframe ............................................................................................................................................... 20

Communications .............................................................................................................................................................................. 23
Electrical Power ............................................................................................................................................................................... 24
Equipment/Furnishings .............................................................................................................................................................. 25
Flight Controls ................................................................................................................................................................................... 27
Fuel ............................................................................................................................................................................................................... 28
Indication/Recording Systems ............................................................................................................................................ 31
Landing Gear ........................................................................................................................................................................................ 32
Lights .......................................................................................................................................................................................................... 33
Navigation ............................................................................................................................................................................................... 34
PAGE DATE:
PAGE DATE:1.
16.June
June1995
2008 PAGE F
EXTRA CONTENTS
STRUCTURES
Standard Practices and Structures - General ........................................................................................................... 51

Fuselage ................................................................................................................................................................................................... 53
Stabilizers ............................................................................................................................................................................................... 55
Wings .......................................................................................................................................................................................................... 57
PROPELLER
Propeller .................................................................................................................................................................................................. 61
POWER PLANT
Engine ........................................................................................................................................................................................................ 72
Oil System ............................................................................................................................................................................................... 79
MISCELLANEOUS
Charts ......................................................................................................................................................................................................... 91
Special Equipment .......................................................................................................................................................................... 95
PAGE DATE: 1.
16.June
June1995
2008 PAGE G
FAX MESSAGE
From: ............................................................. Date: ..............................................................
Address: ........................................................................................................................................
.....................................................................................................................................................
Tel. N°: ........................................................... Fax N°: ..........................................................
To: EXTRA-Flugzeugproduktions- und Fax N°: ............................ (49)-2858-913730

Vertriebs GmbH
Aircraft Description:
Type: ......................... Serial No: .................. O Standard Engine
Flight hours: ............... Landings: ................... O other (please specify) ................................
.................................................................
Equipment installed:
O GOMOLZIG Exhaust silencer O P-1000 digital RPM indicator
O MTV-14-B-C/C190-17 4-blade propeller O External power supply
O Steerable tail wheel O Heating system
O Electrical actuated rudder pedal adjust. O other (please specify) ................................
O Accelerometer DSA 12
.................................................................
O ELT Pointer 3000
O Fire extinguisher
Detailed Description of Damage or Problem
PAGE DATE: 16. June 2008

PAGE H
FAX MESSAGE
From: ............................................................. Date: ..............................................................
Address: ........................................................................................................................................
.....................................................................................................................................................
Tel. N°: ........................................................... Fax N°: ..........................................................
To: EXTRA-Flugzeugproduktions- und Fax N°: ............................ (49)-2858-913730

Vertriebs GmbH
Aircraft Description:
Type: ......................... Serial No: .................. O Standard Engine
Flight hours: ............... Landings: ................... O other (please specify) ................................
.................................................................
Equipment installed:
O GOMOLZIG Exhaust silencer O P-1000 digital RPM indicator
O MTV-14-B-C/C190-17 4-blade propeller O External power supply
O Steerable tail wheel O Heating system
O Electrical actuated rudder pedal adjust. O other (please specify) ................................
O Accelerometer DSA 12
.................................................................
O ELT Pointer 3000
O Fire extinguisher
Existing Technical Documentation:

Flight Manual incl. Revisions up to N° ............. Service Manual incl. Revisions up to N° ..........
Language: ....................................................... and Service Bulletins up to S.B. N° .................
Description of optional equipment (see section Maintenance instructions concerning optional
9): equipment (see CH. 95):
O Steerable tail wheel O GOMOLZIG Exhaust silencer
O Electrical actuated rudder pedal adjust. O Steerable tail wheel
O Accelerometer DSA 12 O Electrical actuated rudder pedal adjust.
O ELT Pointer 3000 O ELT Pointer 3000
O P-1000 digital RPM indicator O P-1000 digital RPM indicator
O External power supply O External power supply
O Heating system
Notice:
PAGE DATE: 16. June 2008 PAGE I

EXTRA
Chapter 01
Introduction
PAGE DATE:1. June 1995 CHAPTER 01

PAGE 1
EXTRA Chapter 01
Table of Contents
Chapter Title
01-00-00 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
01-00-01 Trade Marks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
01-10-00 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
PAGE DATE:
DATE:1.
16.June
June 1995
2008 CHAPTER 01
PAGE 2
EXTRA
01-00-00 GENERAL
According to the regulations of the FAR part 23, this service

manual provides educated maintenancestaff with information
necessary for servicing, maintaining and repair of the EXTRA
300L. This manual contains a detailed description of systems
including time limits for the particular components, trouble-
shooting and instructions for the performance of inspection
and maintenance work. The instructions, that are necessary
for disassembly, check, repair, maintenance or overhaul of
vendor equipment are not incorporated in this manual. The
modification instructions ("Umrüstanweisungen") of
installed optional equipment shall be collected in Chapter
95.
Use the following documents in connection with this service
manual:
Aircraft:
• Pilot´s Operating Handbook and Airplane Flight Manual

• Parts Catalogue
• Service Bulletins
• Aircraft Record
• Airplane Log Book and Engine Log Book
NOTE Check the following Airplane Log Book documents are

up-to-date and in accordance with the current national
aviation authority regulations.
Carried in the airplane:

- Aircraft Airworthiness Certificate
- Aircraft Registration Certificate
- Aircraft Radio Station Licence
- Certificate of Insurance
- Weight and Balance Data Sheet and associated papers
- Equipment list
PAGE DATE:
DATE:1.
16.June
June 1995
2008 CHAPTER 01
PAGE 3
EXTRA GENERAL
Engine: Lycoming AEIO-540-L1B5

Lycoming AEIO-540-L1B5/D
Lycoming AEIO-580-B1A
• Operator´s Manual AEIO-540 (P/N:60297-21)

• Operaton and Installation Manual AEIO-580
(P/N:60297-32)
• Maintenance and Overhaul Man. AEIO-580
(P/N: LMO-AEIO-580)
• Service Letters, Bulletins and Instructions INDEX
• Service Letters, Bulletins and Instructions
Manufacturer: LYCOMING ENGINES
652 Oliver Street,
Williamsport, PA 17 701, USA
Propeller: MTV-9-B-C/C 200-15 (3-blade)

MTV-14-B-C/C 190-17 (4-blade)
MTV-9-B-C/C 198-25 (3-blade)
• Operation- and Installation Manual E-124

• Overhaul Manual and Parts List E-220
Governor: P-880-5 and P-880-41
• Operation- and Installation Manual E-1048
Manufacturer: MT-Propeller Entwicklung GmbH,
Airport Straubing, 94348 Atting,
Germany
* refer to the Lycoming Service Magneto: a) SLICK No. 6251 and 6250 *
Instruction No.1374 A and 1374 B
SLICK No. 6351 and 6350
(for Lycoming AEIO-540-L1B)
SLICK No. 6350, and 6393
(for Lycoming AEIO-580-B1A)
• Magneto Maintenance and Overhaul Manual

• Service Bulletins (refer to Lycoming Service Letters,
Bulletins and Instructions INDEX)
PAGE DATE:
PAGE 4. June
DATE:1. June2009
1995 CHAPTER 01
PAGE 4
EXTRA GENERAL
Manufacturer: UNISON INDUSTRIES

530 Blackhawk Part Aveneue
Rockford, IL 61104 , USA
b) BENDIX Model No. D6LN-3000

(for Lycoming AEIO-540-L1B5/D)
• Service Bulletins (refer to Lycoming Service Letters,
Bulletins and Instructions INDEX)
Manufacturer: TELEDYNE CONTINENTAL
MOTORS
P.O. BOX 90 Mobile,
AL 36601,USA
Magneto Start Booster:

SlickSTART SS1001
(for Lycoming AEIO-580-B1A)
• Operation, Maintenance and
Troubleshooting Manual L-1492
Manufacturer: UNISON INDUSTRIES
530 Blackhawk Part Aveneue
Rockford, IL 61104 , USA
Inverted Oil System: CHRISTEN 801 Series (mod.)
• Product Manual (P/N: 70047-001)
Manufacturer: CHRISTEN INDUSTRIE, INC.
1048 Santa Ana Valley Road
Hollister, California 95023, USA
Cleveland Wheels & Brakes
• Maintenance Manual
Manufacturer: Parker Hannifin Corporation
1160 Center Road
Avon, Ohio 44011, USA
PAGE DATE:
DATE:1.
4. June
June2009
1995 CHAPTER 01
PAGE 5
EXTRA
Pointer 3000-10 ELT
• Operation and Installation Instructions

Manufacturer: Pointer Avionics
76 Woolwich St. N.
PO Box 271
Breslau, Ontario
N0B 1M0, Canada
Artex ME406 ELT
• Descriptioon, Operation, Installation and Maintenance

Manual ME406 and ME406HM ELT (P/N: 570-1600)
Manufacturer: Artex Aircraft Supplies
P.O. Box 1270
Canby, Oregon 97013
Other Vendor Equipment
(Vendor publication should be obtained directly from the

vendor.)
• Operation- and Installation Manuals
01-00-01 Trade Marks
Even when the ware or brand names used in this manual are
not marked as registered trade-marks, this does not mean,
that these names are free in the sens of trademark legislation.
PAGE DATE:
DATE:1.
31.June
June 1995
2009 CHAPTER 01
PAGE 6
EXTRA
01-10-00 SAFETY
To keep the security risks during the execution of the

inspection and maintenance work as low as possible, observe
the following points:
• Inspection and maintenance work has to be carried out
only by qualified and authorized personnel.
• The execution has to be in accordance with the respec-
tive national safety requirements.
• Before beginning any work, this service manual has to be
read and understood. In case of doubt or lack of informa-
tion the manufacturer has to be contacted for advice.
• The safety notes given in this manual are to be observed
unconditionally.
Refer to Chapter 02-10-06 for information concerning
safety notes.
PAGE DATE:
DATE:1.
16.June
June 1995
2008 CHAPTER 01
PAGE 7
EXTRA
Chapter 02
How to Use the Service Manual
PAGE DATE: 1. June 1995 CHAPTER 02

PAGE 1
EXTRA Chapter 02
Table of Contents
Chapter Title
02-00-00 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
02-10-00 MANUAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . 3

02-10-01 Manual Set-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
02-10-02 Chapter Set-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
02-10-03 Page Numbering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
02-10-04 Figure Numbering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
02-10-05 Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
02-10-06 Notes/Safety Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
02-20-00 HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
02-20-01 Revisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
02-20-02 Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
02-20-03 Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
02-20-04 Fax-Formats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

PAGE 2
EXTRA
02-00-00 GENERAL
The set-up of the manual, the chapters and the handling

correspond to the regulations of the Air Transport Associa-
tion of America, ATA Specification No. 100. Only the num-
bering of the pages and the layout have been changed to make
working with this manual easier.
02-10-00 MANUAL DESCRIPTION
02-10-01 Manual Set-Up
The manual consists of groups, which are subdivided in

chapters. Additionally there are preceding pages, which
contain the List of Effective Pages, the Lists of Service
Bulletins and the Record of Revisions. In the list of chapters
the groups are marked by capital characters.
02-10-02 Chapter Set-Up
The chapter numbering system used in this manual repre-

sents the chapter set-up. It is a conventional dash-number
breakdown. The number is composed of three elements
which consist of two digits each:
02-10-02
chapter - section - subject
The first element shows the chapter (here: "How to Use the
Service Manual"). The second element shows the first sub-
division, which is called "section" (here: "MANUAL DE-
SCRIPTION"). The third element shows the "subject", which
is handled within the respective section (here: "Chapter Set-
Up"). The first three digits refer to the definitions of the ATA
Specification 100, where they exist; the other digits are

PAGE 3
EXTRA
defined by the manufacturer. If a more detailed breakdown is

necessary, bold faced headlines like the following are used:
Powerplant
02-10-03 Page Numbering
The page numbering begins at the coversheet of each chapter

with "Page 1". In contrast to the ATA Specification 100, the
particular sections and subjects don't start with a new
numbering.
02-10-04 Figure Numbering
The figures are numbered in such a way that the first figure
in each chapter starts at "Figure 1".

PAGE 4
EXTRA MANUAL DESCRIPTION
02-10-05 Layout
Apart from the headers and footers the layout consists of two
columns. The right column contains text, titles, tables,
schedules and figures (figures also can fill the whole page);
the left column contains the chapter numbering, boxed
textmarkers for notes and safety notes as well as explana-
tions. The following figure1shows more details:
1 manufacturer´s masthead and

manual title
2 section and subject titles
3 chapter numbering
4 title
5 bar marking revised parts
6 boxed textmarker for notes and

safety notes
7 explanations e.g. to tables
8 figure title and number
9 date of first issue resp. last

revision
10 chapter and page numbers
Layout
Figure 1

PAGE 5
EXTRA MANUAL DESCRIPTION
02-10-06 Notes/Safety Notes
Safety notes in this manual are marked by a boxed textmarker

in the margin column and written in semi-bold characters.
This manual distinguishes three warning levels:
DAN GE R Represents an threatening danger for the personnel.

The non-observation of this safety note will result in
death or serious injuries.
WAR N I N G Represents a possibly dangerous situation for the per-

sonnel. The non-observation of this safety note may re-
sult in injuries.
CAUT I O N Represents a danger to equipment. The non-observa-

tion of this safety note results in destruction of equip-
ment. This safety note does not exclude a possible dan-
ger for the personnel.
Additional information given in this manual are also marked

by boxed textmarkers in the left column and are written in
semi-bold characters:
I M PO R TAN T Represents an important hint. Often used when the non-

observation could endanger pilot or passengers during
flight.
NOTE Represents an useful or remarkable hint.

PAGE 6
EXTRA
02-20-00 HANDLING
02-20-01 Revisions
Service/Maintenance Manuals and other Technical

Publications in current revision status are available over the
World Wide Web (direct link http://www.extraaircraft.com/
techserv.asp). Cross-check your documents against these
publications and replace pages as necessary. Paper copies of
publications will continue to be available if this is your
preferred format of publications. Orders can be placed by
contacting Extra Aircraft
at e-mail: ExtraAircraft@ExtraAircraft.com
or facsimile: +49-(0) 2858-9137-30.
NOTE Pages of this SERVICE MANUAL may not be exchanged

and no alterations of or additions to the approved
contents may be made without the EXTRA Flugzeug-
produktuions- und Vertriebs GmbH/EASA approval.
If revision of pages is necessary, observe the following steps:
NOTE Change revised pages immediately upon receipt.
1 Take out the old pages and destroy them.

2 Insert the new pages following the chapter and page
numbers.
3 Replace the old pages "A-C = List of Effective Pages".
4 Enter the date on page "D = Record of Revision" and on
page "2 = Record of Revision" of Ch. 04 if necessary.
Each revised page is marked at the bottom by the date of
revision; revised parts of the new page are marked by a bar on
the left margin.
02-20-02 Service Bulletin
The Service Bulletins describe which procedures and how

and when they are to be carried out. Enter the receipt of each
Service Bulletin in the Service Bulletin List (page E).
PAGE DATE:
DATE: 31.
1. June 2009
1995 CHAPTER 02
PAGE 7
EXTRA HANDLING
NOTE The owner is responsible for incorporating Service

Bulletins to the above mentioned Service Bulletins
List (page E).
02-20-03 Checklists
Observe the following steps when working with checklists:

1 Copy the respective check list for performing a check.
2 Enter the date at the top of the table.
s rs Date: Inspector:
e d our hou
if i h 0 Serial No.: Mechanic:
p ec h 50 10
s c c h
as ea ea Inspections
1
O O O Text
3 Select the items to be worked out. The "O" at the begin-

ning of the line is written in the column which indicates
the point of time when an item has to be worked out.
Specification for the first column are given by footnotes.
4 Work out the particular items and sign after execution
(responsible mechanic and inspector) using the respec-
tive boxes behind the item.
5 After completion of the inspection check file the list with
entries in the Aircraft Records.
6 Certify the completion of check in the Aircraft Log Book.
02-20-04 Fax-Formats
When contacting EXTRA-Flugzeugproduktions- und

Vertriebs-GmbH is advisable in case of questions and/or
problems during maintenance of aircraft copy and use one of
the fax-formats you find on the preceding pages ("H-I") for
correct identification of aircraft, equipment and existing
technical instructions. The data we request there are helpful
for us to provide you with the information you need.
DATE: 31.
1995 CHAPTER 02
PAGE 8
EXTRA
Chapter 03
General Description

PAGE 1
EXTRA Chapter 03
Table of Contents
Chapter Title
03-00-00 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
03-10 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
03-10-01 Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
03-10-02 Flight Control System . . . . . . . . . . . . . . . . . . . . . . . . . . 4
03-10-03 Brake System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
03-10-04 Powerplant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
03-10-05 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
03-10-06 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
03-10-07 Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

PAGE 2
EXTRA
03-00-00 GENERAL
This chapter shows a short survey of the particular systems.

A more detailed description of the systems you find in the
respective chapters (see: CONTENTS).
The Extra 300L (refer to Figure 1) is designed as a light
weight, single-engine, two seat, low-wing monoplane using
composite and steel materials. It has a fixed main landing
gear and a tail wheel unit with full-swivel capability.
View EXTRA 300L

Figure 1

PAGE 3
EXTRA
03-10 DESCRIPTION
03-10-01 Construction
Manufacturer: EXTRA-FLUGZEUGBAU GmbH

Flugplatz Dinslaken
D-46569 Hünxe, Germany
Fuselage: steel tube design, covered with
fabric, composite material resp.
aluminium sheet metal,
single piece canopy side hinged
Wing: fibre composite design
Stabilizers : fibre composite design
Landing gear: 2 main wheels, 1tail wheel, fibre
composite strut design
Seats
Rear Seat: Seat to pedal distance, seat angle

and seat back rest adjustable, 5
piece harness
Front seat: non variable position, 5 piece
harness
03-10-02 Flight Control System
Pitch control: push-pull rods

Roll control: push-pull rods
Yaw control: cable system
Pitch trim: trim tab on the right elevator,
bowden cable

PAGE 4
EXTRA DESCRIPTION
03-10-03 Brake System
Main wheels: hydraulically operated disc brakes,

hydraulic cylinders actuated by
brake pedals
Tail wheel: no brake
03-10-04 Powerplant
Engine
Manufacturer: TEXTRON LYCOMING

Williamsport Division
652 Oliver Street
Williamsport Plant 17 701
USA
Type: AEIO-540-L1B5
(6 cyl. air cooled, fuel injection,
independent magneto ignition
system, inverted flight oil system,
special antivibration counter
weights)
Rated power: 300 hp at 2700 rpm
or: AEIO-540-L1B5D
(Same as engine AEIO-540 L1B5,
but double magneto)
or: AEIO - 580-B1A
(6 cyl. air cooled, fuel injection,
independent magneto ignition
system, inverted flight oil system,
special antivibration counter
weights, retard breaker magneto,
Slick Start system)
Rated power: 315 hp at 2700 rpm
PAGE DATE:
DATE:16.
1. January 2009
June 1995 CHAPTER 03
PAGE 5
EXTRA DESCRIPTION
SERVICE MANUAL EXTRA 300L Powerplant
Propeller
Manufacturer: MT Propeller Entwicklung GmbH

& Co. KG
Airport Straubing
D-94348 Atting, Germany
Type: MTV-9-B-C/C 200-15
(3-blade wood composite,
hydraulic variable pitch with con-
stant speed regulator,
Propeller diameter: 200 cm)
Optional: MTV-14-B-C/C 190-17
(4-blade, wood composite,
or: MTV-9-B-C/C 198-25
(3-blade wood composite,
03-10-05 Fuel System
Tanks: 2 integral wing tanks, 1 center and 1

acro tank behind the firewall (cock-
pit side)
Fuel supply: mechanical engine driven pump,
additional electrically operated
boost pump,
PAGE DATE:
DATE: 16.
1. June
January
1995
2009 CHAPTER 03
PAGE 6
EXTRA DESCRIPTION
03-10-06 Electrical system
Power supply: engine driven 12 V alternator,

integrated DV converter, 28 Ah
starter battery, master switch
Circuits: equiped with automatic circuit
breakers
Ignition: magneto system, independent from
electrical power supply
03-10-07 Instruments
Standard (minimal) equipment installed (X):
DATE: 16.
January 2009 CHAPTER 03
PAGE 7
EXTRA - FLUGZEUGBAU GmbH
Chapter 04
Airworthiness Limitations
PAGE DATE: 31. January 1995 CHAPTER 04

PAGE 1
Record of Revisions Chapter 04

Rev. LBA Approval Date and
Date of Revision Revised Pages Description of Revision
No. Sign of Approval
— 31. January 1995 — First Edition

PAGE 2
SERVICE MANUAL EXTRA 300L Chapter 04
Table of Contents
Chapter Title
04-00-00 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
04-00-01 Temperature Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
04-00-02 Operating Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
04-10-00 LIFE LIMITED COMPONENTS . . . . . . . . . . . . . . . . 6

04-10-01 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
04-10-02 Replacement Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
04-10-03 Service Life Limited Components . . . . . . . . . . . . . . . . . 6
04-20-00 MAJOR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 7

PAGE 3
04-00-00 GENERAL
For each inspection listed here, refer to the applicable

Chapter in this manual.
I M PO R TAN T It is the operator's responsibility to make sure that time

limits or life limits for items in this chapter are not
exceeded.
The airworthiness limitations items include mandatory

replacement times and structural inspection intervals which
may only be changed with permission of the applicable
airworthiness authority.
This airworthiness limitation section is approved by the
regulatory authority and specifies maintenance required
under paragraphs 43.16 and 91.403 of the Federal Aviation
Regulations, unless an alternative program has been ap-
proved by the regulatory authority.
04-00-01 Temperature Limit
Composite structure is qualified up to 72°C (162°F). Struc-

ture temperatures above this limit are not approved. Not to
exceed this temperature limit, only appropriate colour speci-
fication for composite structure as given by the manufac-
turer document EA-03205.19 must be used when finish
restoration is required.
In case of doubt regarding to the classification of colour,
contact EXTRA-FLUGZEUGBAU GmbH.
04-00-02 Operating Time
Only the airframe and components as listed in Chapter 04-

10-00 are subject to a permissible operating time; concern-
ing all other components recommended replacement times
are given in Chapter 05-10-03.

PAGE 4
EXTRA - FLUGZEUGBAU GmbH GENERAL
SERVICE MANUAL EXTRA 300L Operating Time
The reliability of the composite primary parts has been

convincingly demonstrated by fatique testing (Two times
design life 2x6000 = 12000 hrs).
I M PO R TAN T Every 1000 flight hours the "Significant Items Inspec-

tion" contained in Chapter 05-30-00 of this manual must
be performed. This 1000 hours inspection releases the
aircraft for further 1000 hours operation, up to max. of
6000 hours.
I M PO R TAN T Prior to 6000 flight hours the "Major Inspection" con-

tained in Chapter 04-20-00 must be performed. This in-
spection may release the aircraft for further operation,
subject to approval of the regulatory authority.

PAGE 5
04-10-00 LIFE LIMITED COMPONENTS
04-10-01 General
The replacement time of the life limited components listed

in Ch. 04-10-02 must be accomplished not later than the
specified period of operation for that component or in
accordance with the manufacturer´s service data or airwor-
thiness directives.
04-10-02 Replacement Time
Items shown here must be replaced during the regular

maintenance periods.
Item R eplace
Wing 6000 h
Aileron 6000 h
Vertical Stabilizer 6000 h
Rudder 6000 h
Horizonal Stabilizer 6000 h
Elevator 6000 h
Landing Gear Spring 6000 h
04-10-03 Service Life Limited Components
The service life of the EA 300L composite structure as listed

in section 04-10-02 has been set to 6000 flight hours. A
"Major Inspection" on reaching 6000 flight hours may pro-
vide the necessary clearance for further flight. This "Major
Inspection" is contained in Chapter 04-20-00.

PAGE 6
04-20-00 MAJOR INSPECTION
The EXTRA 300L has been manufactured utilizing the latest

knowledge of composite construction and requires new
experience about those parts subject to wear. Until now
insufficient experience about this point has been acquired.
When such information is available it will be accomodated
in later revisions of this manual and will include a major
inspection procedure.

PAGE 7
EXTRA
Chapter 05
Time Limits/Maintenance Checks

PAGE 1
EXTRA
Table of Contents
Chapter Title
05-00-00 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
05-10-00 TIME LIMIT COMPONENTS . . . . . . . . . . . . . . . . . . 4

05-10-01 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
05-10-02 Overhaul Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
05-10-03 Recommended Replacement Times . . . . . . . . . . . . . . . . 5
05-10-04 Time Between Inspection. . . . . . . . . . . . . . . . . . . . . . . . 6
05-20-00 SCHEDULED MAINTENANCE CHECKS . . . . . . . . 7

05-20-01 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
05-20-02 25 Hour Inspection - Engine . . . . . . . . . . . . . . . . . . . . . 7
05-20-03 25 Hour Inspection - Aircraft . . . . . . . . . . . . . . . . . . . . 7
05-20-04 Maintenance Checks Schedule . . . . . . . . . . . . . . . . . . 12
05-20-05 Significant Items Inspection . . . . . . . . . . . . . . . . . . . . 29
05-50-00 UNSCHEDULED MAINTENANCE CHECKS. . . . . 37

05-50-01 Violent Stopping of the Engine (Propeller Strike) . . . . 37
05-50-02 Hard Landing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
05-50-03 Engine Fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
05-50-04 Lightning Strike . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
05-50-05 Flightline Inspections . . . . . . . . . . . . . . . . . . . . . . . . . 40
PAGE DATE: 15.

16. December
January 2009
2005 CHAPTER 05
PAGE 2
EXTRA
05-00-00 GENERAL
This chapter contains charts for time limits, scheduled

maintenance and unscheduled maintenance, and enables li-
censed personnel to carry out correct inspections on the
EXTRA 300L. The periodic inspections and checks de-
scribed and their recommended time intervals are minimum
requirements for maintaining the aircraft in an airworthy
condition. Further information will be given by the informa-
tion service (Service Bulletins, Service Letters, etc.).
If operation of aircraft requires more frequent servicing, the
check intervals may be shortened. However the check
intervals must not be exceeded without explicit permission
from the regulatory authority. Additional checks as well as
changes must also be agreed by the regulatory authority.
In general this Manual does not give any information about
vendor equipment. Such information can be taken from the
vendor equipment maintenance instructions (refer to Chap-
ter 01). However for practicability reason most of the
applicable vendor equipment inspections are incorporated
in the following checklists. But it has to be noted that the
latest editions of inspections given by the vendors remain
decisive. So, before beginning an inspection, the inspections
of vendor equipment presented here must be compared with
the originals referenced under the respective headlines of
the checklists, and, in case of doubt (e.g. if originals have
changed before changes could be transferred to this Manual
by the Revision Service), contact EXTRA-Flugzeug-
produktions- und Vertriebs- GmbH for advice. The
maintenance instructions referenced in the checklists are
also valid if further inspection of vendor equipment is
necessary.
NOTE For working with checklists refer to Chapter 02-20-

03.
DAN GE R Do not rotate the propeller nor allow any person to stay
in the propeller operating area when performing an in-
spection or check with the master switch "ON" and the
battery connected. The engine may be started un-
intentionally and may cause serious injuries or death.

PAGE 3
EXTRA
05-10-00 TIME LIMIT COMPONENTS
05-10-01 General
All components not listed herein should be inspected as

detailed in Chapter 05-20 „Maintenance Checks“ and re-
paired, overhauled as required. It is recommended that
overhaul or replacement of components should be accom-
plished not later than the specified period of operation for
that component or in accordance with the manufactures
service data or airworthiness directives.
05-10-02 Overhaul Schedule
Items shown here must be overhauled at the times indicated.
Ite m Ove rhaul
* refer to latest issue of Engine *

Manufacturer´s Service Bulletin (Textron Lycoming)
Engine accessories together with engine
Magneto *
(Slick)
Double magnetos *
(Bendix)
Propeller *
(MT- Propeller)
Governer *
(Woodward or MT- Propeller)
All other components on Condition

PAGE 4
EXTRA TIME LIMIT COMPONENTS
05-10-03 Recommended Replacement Times
It is recommended to replace the items shown in the following

schedule at the times indicated. The times may be modificated
by the respective national authorities.
** on the recommendation
of the manufacturer
*** if not stated otherwise
PAGE DATE:
PAGE DATE:16.
31.January
June 2009
2009 CHAPTER 05
PAGE 5
EXTRA
05-10-04 Time Between Inspection
Inspect these equipment items at the times shown:
Ite m Time be twe e n Ins pe ction
Battery (Concorde) Refer to Concorde Servicing

Instruction (capacity check)
Static Pressure System Every 2 years in accordance with
14 CFR Ch. 1 Part 43 App. E
ATC Transponder Every 12 months in accordance
with 14 CFR Ch. 1 Part 43
App. F Par. C and F.

PAGE 6
EXTRA
05-20-00 SCHEDULED MAINTENANCE CHECKS
05-20-01 General
Scheduled maintenance checks or tasks must be carried out

at 25, 50, 100, 200, 300, 400, 500 and 1000 hour intervals.
In addition an annual inspection equal to the 100 hour
inspection has to be performed.
The following pages show a drain hole chart (Figure 1) and
lubrication charts (Figures 2 - 4) which can be used in
connection with the checklists.
05-20-02 25 Hour Inspection - Engine
A 25 hour inspection is necessary for the engine, because the

engine is not equipped with an external oil filter. Therefore
the engine oil has to be changed and the oil screen cleaned
after every 25 hours. Refer to Figure 2 "Lubrication Chart 25
hours".
05-20-03 25 Hour Inspection - Aircraft
After the first 25 hours, a check equal to the 100-hour

maintenance check has to be performed. Refer to Chapter
05-20-04.

PAGE 7
EXTRA SCHEDULED MAINTENANCE CHECKS
1. Root Rib Aileron

2. Root Elevator
3. Root Horizontal Stabilizer
4. TrimTab (3 Holes)
5. Stall Warn Transducer
6. Lower Root Rudder Fin
7. Lower Root Rudder Horn
8. Wheel Fairing
9. Nose Ribs Aileron (Hinge Gaps)
Drain and Vent Holes

Figure 1

PAGE 8
Lubrication Chart 25 hours

Figure 2

PAGE 9

Figure 3

PAGE 10

Figure 4

PAGE 11
05-20-04 Maintenance Checks Schedule
The maintenance checks described in this Chapter include

all the scheduled checks which must be performed. Use the
following schedule and the lubrication charts (Figures 2-4).
e d our hou
ifi h 0 Serial No.: Mechanic:
p ec 50 10
s c h h
as ea eac Inspections
Operational Checks
O O 1 Start engine (in accordance with the Pilot`s Operating Handbook)
O O 2 Check the fuel quantity indication.
O O 3 Check oil pressure and temperature.
O O 4 Check generator output.
O O 5 Check magneto RPM-drop at 1800 RPM. (Allowed drop is
175 RPM and no greater diff. between L + R from 50 RPM)
O O 6 Check ignition OFF function at 1000 RPM for a short mo-
ment.
O O 7 Check response of the engine by power setting changes.
O O 8 Check the Propeller response at 1800 RPM when changing
pitch.
O O 9 Check idle speed is between 650 and 750 RPM.
O O 10 Check the fuel flow and manifold pressure indicator.
O O 11 Check the EGT and CHT indicator.
O O 12 Check mixer function per CHT/EGT indication.
O O 13 Check idle mixture.
O O 14 Check the function of the fuel selector valve.
O O 15 Check the radio and the other electronic equipment.
O O 16 Shut down engine using mixture lever. Check the alternator
warning light or ammeter.

PAGE 12
SERVICE MANUAL EXTRA 300L Maintenance Checks Schedule
rs rs Date: Inspector:
e d hou hou
ifi 0 0 Serial No.: Mechanic:
p ec h 5 10
s c h
as e eac a Inspections
O O 17 Check optional electronic g-meter for the maximum g-
loading. If extreme value exceeds ±10 G, contact EXTRA-
Flugzeugproduktions- und Vertriebs- GmbH. Correct date and
time (refer to DSA-12 Manual).
O O 18 Ignition OFF, main switch OFF, remove ignition key.
O O 19 Check if ignition key is removable in OFF-position only, and
if key functions in accordance with the requirements of the
Teledyne Continental Service Bulletin No. 636.
Propeller
(refer to latest edition of MT-Propeller Operation and Instal-
lation Manual E-124 and Service Bulletins)
Ground magneto primary circuit before
DAN GE R
working on propeller
O 1 Remove spinner and check for cracks.
O O 2 Check blade shake, max. 3 mm or 1/8 inch.
O O 3 Check blade angle play, max. 2°.
O 4 Inspect outside condition of the hub and parts for cracks,
corrosion, deterioration.
O 5 Inspect check nut for high pitch stop for tightness.
O O 6 Check all safety means to be intact.
O O 7 Check flange bolts or stopnuts for tightness.
O 8 Check front and rear spinnerplate for cracks and fixing.
O O 9 Inspect bladeroot and hub for oil- and grease leaks.
O 10 Check position and condition of counterweights.
O O 11 Check blades for cracks in the fibreglass-cover and blade
erosion sheet. No cracks allowed. Refer to MT-Propeller SB
No. 8
1
O 12 Overhaul propeller or perform a tear-down inspection.
1 refer to MT-Propeller Service Bulletin No. 1

PAGE 13
e d our hou
p ec 50 10
s c h ch
Engine compartment
(Refer to latest edition of Textron Lycoming Operator´s and
Maintenance Manual and SB's, Christen Product Manual 801
Series and SB's, Slick Magneto Maintenance and Overhaul
Manual and SB's and TCM/Bendix Service Support Manual,
included in Form X40000 Master Service Manual and SB's)
Ground magneto primary circuit before
DAN GE R
working on engine
O O 1 Remove engine cowling.
O O 2 Inspect cowling and air inlet screen for damage, cracks,
distortion, overheated areas and loose or missing blindnuts
and secure attachment of oil level access plate.
O O 3 After this inspection clean cowling.
O O 4 Check fire protection according to EXTRA Service Bulletin
300-6-94. If necessary repaint the fire protection paint
("WIEDOFLUGAT" Brandschutzfarbe N 56582 / T508).
O1 O O 5 Drain oil sump in accordance with Chapter 12-10-04 “Engine
Oil Replenishing”
1
O O O 6 Clean and inspect oil screen filter
1
O O O 7 Clean suction oil strainer at oil change (check strainer for
foreign particles).
1
O O O 8 Clean pressure oil strainer (check for foreign particles)
O2 O O 8a Change full flow (cartridge type, AEIO-540-L1B5/D engine)
oil filter element (check element for foreign particles).
O 9 Inspect oil temperature sensor unit for leaks and security.
O O 10 Inspect flexible oil lines, oil return lines and fittings for leaks,
security, chafing, dents, and cracks (ref: FAA AC 43.13-1A).
Replace flexible oil lines at engine TBO per Lyc. SB 240.
Check fire protection according to EXTRA SB 300-6-94.
O 11 Clean and inspect oil radiators and attachment.
O3 12 Remove and flush oil radiators.
1 at 10 and 25 hours and then each 25 hours
2 at 10 and 25 hours
3 each 500 hours
PAGE 14
e d
o ur hou
ifi
c
h
0 00 Serial No.: Mechanic:
s pe h 5 h 1
c Inspections
as ea eac
O O Inspect Christen Inverted Oil System for general condition,
leaks, secure mounting and tight connections.
O1 13 Clean and flush the Inverted Oil System with a suitable
petroleum solvent, such as varsol according to Lycoming
Operator’s and Maintenance Manual.
O2 O O 14 Service engine with recommended lubricating oil in accord-
ance with Chapter 12-10-04.
O O 15 Inspect condition of spark plugs (Clean and adjust gap as
required, adjust per Lycoming Service Instruction 1042). If
fouling of spark plugs has been apparent, rotate buttom plugs
to upper plugs and vice versa.
O O 16 Inspect spark plug cable leads and ceramics for corrosion and
deposits.
O O 17 Perform a hot engine differential compression check in
accordance with FAAAC 43.13-1A.
O 18 Inspect cylinders for cracked or broken fins.
O O 19 Check cylinders for evidence of excessive heat which is
indicated by discoloration.
O 20 Check fuel injector nozzles for loseness. Tighten to 60 inch
pounds torque. Check fuel lines for fuel stains which are
indicative for fuel leaks.
O O 21 Inspect rocker box covers for evidence of oil leaks. If found,
replace gasket; torque cover screws 50 Inch-pounds.
3
O 22 Remove rocker box covers and check for freedom of valve
rockers when valves are closed. Look for evidence of abnor-
mal wear or broken parts in the area of valve tips, valve keeper,
springs and spring seats.
O 23 Inspect ignition harness for general condition, free from
fraying or chafing and insulators for high tension leakage and
continuity.
1 each 300 hours

2 each 25 hours
3 each 400 hours
PAGE 15
e d
o ur hou
ifi
c
h
s pe h 5 h 1
c Inspections
as ea eac
TCM/Bendix magnetos
O 24 Check magneto-to-engine timing.
O 25 Remove all ignition harness spark plug terminals from spark
plugs, clean and inspect following the respective sections of
the applicable Support Manual.
O 26 Inspect magnetos with riveted impulse coupling for wear as
specified in the latest revision of TCM/Bendix SB 599D.
1
O 27 Inspect magnetos equipped with snap-ring impulse coupling
for wear as outlined in the PERIODIC MAINTENANCE Section
of the applicable Support Manual, Paragraph 6.2.2.
O1 28 Inspect magnetos as outlined in the PERIODIC MAINTE-
NANCE Section of the applicable Support Manual, Paragraph
6.2.3. Clean and inspect all ignition harness outlet plates,
covers or cap assemblies and grommets following the
respective sections of the Manual mentioned above.
O2 29 Overhaul or replace magnetos acc. to TCM/Bendix SB 643.
Slick magnetos
O 24 Adjust magneto to engine timing, refer to Slick Magneto
Maintenance and Overhaul Manual
O 25 Inspect wiring connections, vent holes and P-lead
attachment, refer to Slick Magneto Maintenance and Overhaul
Manual.
O 26 Inspect SlickSTART, refer to Unison Operation, Maintenance,
and Troubleshooting Manual. (AEIO-580-B1A engine only)
1
O 27 Clean magnetos.
O1 28 Inspect ball bearing assembly, impulse coupling, coil, contact
points, condenser and carbon brush.
O3 29 Replace ball bearings.
O1 30 Lubricate magnetos.
4
O 31 Overhaul or replace magnetos.
1 each 500 hours
2 at engine overhaul and at the expiration of 4 years
3 each 1000 hours
4 together with engine
PAGE 16
e odur hou
ifi
c
h
s pe h 5 h 1
c Inspections
as ea eac
O 32 Check fuel injector for general condition, clean fuel inlet
screen.
O O 33 Inspect intake seals and O-rings for leaks and clamps for
tightness.
O O 34 Inspect flexible fuel lines, fuel injection lines and fittings for
leaks, security, chafing, dents, and cracks ( refer to Lycoming
SB 342 each 100h; replace or overhaul as required or at engine
overhaul). Check fire protection according to EXTRA SB
300-6-94.
O O 35 Check fuel system for leaks.
1
O O O 36 Remove, clean and inspect gascolator screen and fuel filter
bowl.
O O 37 Inspect throttle, mixture, and propeller governor controls for
security, travel, and operating conditions.
O O 38 Inspect exhaust stacks, connections and gaskets (replace
gaskets as required).
O O 39 Inspect exhaust slipjoints for general condition.
O O 40 Inspect exhaust system attachment.
O 41 Inspect crankcase for cracks, leaks, and security of seam bolts.
O O 42 Check engine mounted accessories such as pumps, tempera-
ture and pressure sensing units for leaks, secure mounting and
tight connections.
O O 43 Inspect engine mount for cracks and loose mountings.
O O 44 Inspect engine baffles free from cracks and fraying.
O 45 Inspect all wiring connected to the engine or accessories
O O 46 Inspect engine shock mount for deterioration (replace as
required).
O 47 Inspect firewall seals (see EXTRA SB 300-6-94).
O 48 Inspect alternator, cable connections and accessories.
O 49 Inspect condition and tension of alternator drive belt
1 clean at least every 90 days

PAGE 17
EXTRA
s Date:
rs our Inspector:
ed
f i h o u h
ci 0 00 Serial No.: Mechanic:
s pe h 5 ch 1
c Inspections
as ea ea
O 50 Inspect security of alternator mounting
O 51 Inspect starter and starter drive
O O 52 Check brake fluid level (fill as required).
O O 53 Clean engine if necessary.
O O 54 Lubricate all controls per lubrication chart.
O1 55 Overhaul or replace propeller governor as required.
O2 56 Complete overhaul of engine or replace with factory rebuilt
O O 57 Reinstall engine cowling.
1 refer to Woodward Service Bulletin No. 33580

2 refer to Lycoming Service Instruction No. 1009

PAGE 18
e d
o ur hou
ifi
c
h
s pe h 5 h 1
c Inspections
as ea eac
Fuselage
O O 1 Remove tail fairing, tail side skins, main fuselage cover and
landing gear cuffs per Chapter 51.
O 2 Remove bottom fuselage cover including exhaust area cover-
ing sheet per Chapter 51.
O O 3 Inspect main fuselage cover, bottom fuselage cover including
exhaust area covering sheet, tail fairing, tail side skins and
landing gear cuffs for general condition, dents, cracks and
loose screws.
O O 4 Check installed parts for general condition and security of
attachment.
O O 5 Inspect fuselage for foreign matters.
O 6 Inspect steel tube construction for general condition, corro-
sion and cracks, above all in areas of load stress (e.g. wing,
stabilizer, engine and seat attachments).
O O 7 Visually inspect steel tube construction in the area of horizon-
tal stabilizer attach brackets for cracks. In case of doubt
remove horizontal stabilizer and use a dye check penetrant. In
case of cracks are found contact EXTRA-Flugzeugproduktions-
und Vertriebs- GmbH for repair advise.
O O 8 Inspect fabric cover for general condition.
O 9 Inspect wooden longerons for damage.
O 10 Clean and lubricate canopy hinge and latching mechanism.
O 11 Inspect breather line for obstructions and security.
O 12 Inspect main and auxiliary wing spar connector for general
condition.
O O 13 Inspect seats for security, attachment, proper operation, and
condition.

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Seat belts
O 1 Check seat belts for security, attachment, proper operation,
and condition.
O 2 Check webbing; inspect for fuzzy edges at the adjusters,
inspect whether edges start to fray, inspect whether webbing
lost its color (topside a different shade than the bottom side).
O 3 Check hardware; inspect for corrosion, check whether buckles
mate properly. Check the buckles for easy opening .
O 4 Check ratchet assembly; inspect for corrosion, loss of plating,
discoloration, slippage and wear; check for ease of operation.
If the harness does not pass the check, it has to be reworked or
replaced. Contact the harness manufacturer in case of doubt.
Fuel system
O O 1 Inspect the fuel lines for leaks, security, chafing, dents and
cracks. Replace fuel lines as required.
O O 2 Inspect fuel selector valve for operation and proper pointer
indication
O O 3 Drain fuel system
O O 4 Check acro- and center tank attachment
O O 5 Check acro-, center- and both wingtanks for leaks
O O 6 Check boost pump
O O 7 Check fuel filler caps for security and proper operation
O O 8 Check proper seat and condition of sealing lip

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Flight controls
O O 1 Remove wing access panels.
O O 2 Inspect control surfaces for security of attachment, free
movement, dents, delaminations and cracks.
O O 3 Check spades visually for general condition. Inspect spade
support for corrosion, cracks and deformations. Ensure proper
attachment to aileron.
O O 4 Inspect elevator trim system for proper operation and rigging.
O O 5 Inspect hinges for condition, cracks and security; hinge bolts,
hinge bearings, selflocking nuts.
O O 6 Check free play in control system: torque tube, control surfaces,
control sticks, rod end bearing, deflector limiter.
O1 O O 7 Lubricate rear torque tube bearing.
O O 8 Lubricate aileron rodend bearings, trim flap hinges and trim
lever bolt.
O 9 Lubricate adjustment tube of electrical pedal adjustment.
O O 10 Check rudder cable system including sleeves, fairleads, pulleys
and cable retracting springs per FAA-AC 43.13-1A.
O 11 Check for minimum 3.5 mm (1/8") clearance of rudder pedal
versus safety stop when fully deflected for rudder cables
having 50 h flight time minimum. On newly installed rudder
cables the minimum spacing is 6 mm (1/4"). Refer to Figure 5.
This check is to be performed with zero loading on the rudder
pedals.
O 12 Rough check of safety stop clearance. With a force of approx.
90 kg (200 lbs) acting on the fully deflected rudder pedal the
safety stop shall not be reached. If the stop is reached the
control system indicates a too high flexibility which needs to
be traced. In this case contact EXTRA for advice.
O O 13 Inspect all flight control ventilation holes for obstruction.
O 14 Inspect elevator balance weight for looseness and condition.
O 15 Inspect push rods.
1 each 25 hours
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Landing gear
O O 1 Check landing gear for general condition.
O O 2 Check landing gear spring for dents and cracks.
O O 3 Inspect landing gear spring mounting clamps and bolts for
security.
O 4 Lubricate landing gear center bolt and landing gear bearings.
O 5 Check wheel rake (10° ± 0.5°) and toe-in (1.5° ± 0.5°) per
Chapter 32.
Fairings:
O O 1 Disassemble fairings.
O O 2 Check fairings for dents and cracks.
O O 3 Check fairing ventilation hole for obstruction.
Wheels
(refer to on-aircraft inspections presented in the latest edition
of Cleveland Wheels & Brakes Maintenance Manual and
Service Bulletins for wheel, tire and break inspections)
O O 1 Visually inspect the wheels for corrosion, cracks, or other
visible damage.
O O 2 Check wheel nuts to be sure they are properly installed and
have not worked loose. Bolt threads should be flush to 1-1/2
threads extending beyond the nut. Nuts should be on the side
of wheel opposite the brake disc (outboard side of wheel).
O O 3 Inspect the brake disc for rust, excessive grooves, large cracks,
coning or other visible damage. Check if disc thickness is
more than 0.325in/8.255mm. Coning of disc in excess of
0.015 in /0.381 mm is cause for replacement (see Fig. 6).
O 4 Remove wheels and wheel bearings. Inspect wheel bearing
grease for contamination and solidification.

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O 5 Inspect snap rings and grease seals for distortion or wear.

Replace grease seal felts if they are hard or contaminated.
Lightly saturate grease seals should be replaced if cracked,
dried out, or distorted.
O 6 Inspect wheel bearings for excessive wear or damage. Replace
on condition.
O 7 Repack bearings with AEROSHELL 22C (per MIL-G-81322),
or equivalent. Reinstall wheels and safety.
O O 8 Check wheel bearing clearance and wheels for free rotation.
Tires
O O 1 Visually inspect tires for cuts, flat spots, and tread or sidewall
damage. If changing of tires is necessary follow the instruc-
tions, including off-aircraft inspection of wheels, presented in
the Cleveland Wheels & Brakes Component Maintenance
Manual.
O O 2 Check inflation pressure (3.4 bar /49.3 psi). Proper inflation
will provide maximum tire and wheel life.
Brake system
O O 1 Inspect brake assemblies for general condition.
O O 2 Inspect master cylinders for leaks.
O 3 Inspect brake system plumbing for leaks and hoses for bulges
and deterioration.
O 4 Lubricate brake guide pins using Silicone-base lubricant.
O O 5 Visually inspect the brakes for corrosion, cracks, or other
visible damage. Check inlet fitting bosses and anchor bolt lugs
for cracks. Check inlet flares on aircraft side of rigid hydraulic
tubing for fatigue cracks.
O O 6 Check back plate attachment bolts to insure they are properly
torqued and have not worked loose. Gaps between the back
plate and cylinder would be evidence of this.

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O O 7 Check fit of brake cylinder anchor bolts in torque plate

bushings for sloppiness. This can be accomplished by grasping
the cylinder and moving it; slight movement is normal.
Excessive movement is cause for removal and detailed
inspection.
O O 8 Linings should be visually checked for extreme chipping on
the edges. Lining worn to a minimum thickness of 0.100 inch
(2.54 mm) must be replaced.
O O 9 Visually check torque plate for corrosion, cracks, loose anchor
bolt bushings, or other visible damage. Anchor bolt bushings
must be flat against torque plate surface.
O O 10 Check for any brake fluid leaks.
O O 11 Check brake fluid level.
Tail-wheel landing gear
O O 1 Check tail-wheel landing gear for general condition.
O O 2 Check tail-wheel landing gear spring for dents, cracks, and
delaminations.
O O 3 Check tail-wheel rubber tire condition.
O O 4 Inspect tail-wheel spring and swivel arm mounting bolts for
security.
a) Standard: Full-swivel tailwheel
O O 1 Check swivel arm for dents and cracks.
O O 2 Check tail wheel for free rotation and swivel feature.
O 3 Check swivel arm and wheel bearing clearance, service.
b) Optional: Steerable tailwheel
O O 1 Check for general condition and function. Pay attention to the
free movement of the rudder.
O O 2 Check the connector springs for light precompression.

PAGE 24
EXTRA
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O O 3 Check the wheelfork for free rotation and steering function,
damage, dents, cracks and corrosion.
O O 4 Inspect wheelfork for damage, dents, cracks and corrosion.
O O 5 Inspect the axle bolt and nut for fretting, wear, damage, and
stretch.
O O 6 Lubricate tail wheel steering.

PAGE 25
EXTRA
rs Date: Inspector:
e d ours hou
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Wing
O O 1 Check wing for dents, cracks, and delaminations.
O 2 Inspect wing spar main bolts for looseness and security.
O 3 Check the safety wire and the safety screw of the wing main
spar bolt.
O 4 Inspect wing spar main sleeves for looseness and bearing load.
O 5 Inspect wing auxiliary spar attachment.
O 6 Inspect wing ventilation holes for obstruction.
O O 7 Check inside wing structure in the area of access panels.
Stabilizer
O O 1 Check stabilizer for dents, cracks; stone nicks and
delaminations.
O O 2 Inspect stabilizer spars main bolts for looseness and security.
O O 3 Inspect stabilizer auxiliary spars attachment.
O 4 Inspect stabilizer ventilation holes for obstruction.

PAGE 26
EXTRA
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Instruments
O 1 Inspect panel mounting for security and safety.
O 2 Check operation, mounting, and wiring of switches for condi-
tion and safety.
O 3 Check automatic circuit breaker mounting and wiring for
condition and safety.
O 4 Inspect stall warner system for condition and security of

installation, perform operational check.
O O 5 Check wingtip position /strobe lights for security and opera-
tion.
O O 6 Inspect compass and compass deviation card for proper indi-
cation and compensation.
1
O 7 Magnetic compass compensation.
O 8 Check pitot /static air pressure lines for condition and leaks,
perform operational check.
O1 9 Check ASPEN EFD1000 PILOT PFD speed bands for
compliance with instrument markings in the Pilot's Operating
Handbook. Correct data if necessary per ASPEN Installation
Manual.
Electrical system
O O 1 Check engine bonding
O O 2 Check tank bonding (wing- and center tank)
O 3 Check system wiring free from fraying or cracks
O 4 Inspect battery and attachment
O O 5 Charge battery
1 Annual, each twelve calendar month

PAGE DATE:
PAGE DATE:16.
31.January
June 2009
2009 CHAPTER 05
PAGE 27
EXTRA
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General
O1 O O 1 Perform checks given for special equipment installed (refer
to Chapter 95).
O1 O O 2 Perform checks and maintenance for the ELT. Follow the
applicable instructions prepared by the respective ELT
manufacturer (Refer to Chapter 01).
1
O O O 3 Reinstall access panels per Ch. 51.
O1 O O 4 Aircraft conforms to Specifications of respective Authority
O1 O O 5 All required airworthiness directives complied with.
1
O O O 6 All EXTRA mandatory Service Bulletins complied with.
O1 O O 7 All vendor Service Bulletins and Service Letters complied
with.
O1 O O 8 Check for proper flight manual.
O1 O O 9 Aircraft papers in proper order.
Min 3,5mm (1/8")

(Min 6,0mm (1/4")
Rudder Pedal with newly installed
rudder cables)
Safety Wire Hole
Safety Stop
Minimum Clearance Check

Figure 5
Coning Check
Figure 6
1 as required
PAGE DATE:
PAGE DATE:16.
31.January
June 2009
2009 CHAPTER 05
PAGE 28
05-20-05 Significant Items Inspection
Every 1000 flight hours the "Significant Items Inspection"

must be performed in addition to the 100-hour inspection.
Date: Inspector:
urs
ho Serial No.: Mechanic:
00
10 Inspections EXTRA 300L
Wing
Leading edge
O 1 Detailed visual inspection on the surface for erosion, scratches, stone
nicks and impact damages.
O 2 Detailed visual inspection on the bonding top/bottom for dents, cracks
and delaminations.
O 3 Inspect grounding rivets visually.
Main spar section
O 4 Check bonding skin/spar for delaminations by coin tapping (Refer to
Chapter 20-10-05).
O 5 Detailed visual inspection on the sparweb for dents, cracks and
delaminations by visual inspection through wing access holes using a
boroscope.
Auxiliary spar section
O 6 Check bonding skin/spar for delamination by coin tapping .
O 7 Detailed visual inspection on the aux. spar web for dents, cracks and
delaminations. Pay particular attention to the cutout for aileron
cantilever.
O 8 Inspect attachment fitting for damage, corrosion and link bolts security.
Spar carry-through
O 9 Remove spar cap paint by a solvent. Perform visual inspection for dents
and cracks. Check for delaminations by coin tapping. Restore finish in
accordance with Chapter 51-70-05.
O 10 Remove spar web paint by a solvent. Perform visual inspection for
dents and cracks. Check for delaminations by coin tapping. Restore
finish in accordance with Chapter 51-70-05.
O 11 Check main bolt sleeves for secure bonding to the spar.

PAGE 29
SERVICE MANUAL EXTRA 300L Significant Items Inspection
s Date: Inspector:
r
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0 Serial No.:
0
10 Inspections
Wing trailing edge

O 12 Check bonding top/bottom for cracks and delaminations by coin
tapping (Refer to Chapter 20-10-05).
Root and Tip
O 13 Check root rib for cracks, delaminations and secure bonding to skin and
spars by coin tapping (Refer to Chapter 20-10-05).
O 14 Inspect tip rib visually for general condition.
O 15 Check metall fittings (power supply support) for secure bonding to the
carbon laminate
Aileron
O 1 Check root and tip rib bonding to the skin laminate by coin tapping.
O 2 Check bonding skin/spar for delaminations by coin tapping.
O 3 Checkbonding top/bottom for cracks and delaminations by coin tapping
(Refer to Chapter 20-10-05).
O 4 Check hinge points (mounting brackets) and actuator for damages and
cracks. Ensure proper attachment.
O 5 Inspect spades visually for general condition. Check spade support for
corrosion, cracks and deformations. Ensure proper attachment to
aileron.
O 6 Inspect ventilation holes for obstruction.
Surface general
O 1 Check painting visually for general condition (blisters etc.).
O 2 Check laminate for erosion, scratches and nicks.
Control system
O 1 Inspect bell cranks for damage, corrosion, security of mounting and
link bolts through wing access holes.
O 2 Inspect control rods for corrosion.
O 3 Check Rod end bearing for free movement and cleanliness.
Vertical Stabilizer
Leading edge
O 1 Check surface for erosion, scratches, stone nicks and impact damages.
O 2 Check bonding left/right for dents, cracks and delamination.

PAGE 30
s Date: Inspector:
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0 Serial No.:
0
10 Inspections
Front spar section

O 3 Check bonding skin/spar for delamination by coin tapping (Refer to
Chapter 20-10-05).
O 4 Detailed visual sheet metal attachment fitting for damage, corrosion
and link bolts security.
Rear spar section
O 5 Check bonding skin/spar for delamination by coin tapping .
O 6 Detailed visual rear spar web for dents, cracks and delamination. Pay
particular attention to the cut out for rudder cantilever.
O 7 Check steel sleeve for secure bonding to the spar.
O 8 Replace attachment bolts and stop nuts. Check for proper torque in
Root and Tip
O 9 Check root rib for cracks, delamination and secure bonding to skin and
spars by coin tapping.
Rudder
O 1 Check tip rib bonding to the skin laminate by coin tapping.
O 2 Check bonding skin/spar for delamination by coin tapping.
O 3 Check bonding trailing edge for cracks and delaminations by coin
tapping.
O 4 Detailed visual of mounting brackets for damages and cracks. Ensure
proper attachment. Replace bolts and stop nuts for new ones in any
case. Check for proper torque in accordance with Chapter 20-10-02.
O 5 Check actuator lever for damage, cracks and proper attachment.
O 6 Inspect ventilation holes visually for obstruction. Refer to Chapter 05-
20-01, Figure 2 "Drain and Vent Holes".
O 7 Check painting visually for general condition (blisters etc.).
O 8 Check laminate for erosion, scratches and stone nicks.

PAGE 31
s Date: Inspector:
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0 Serial No.:
0
10 Inspections
Horizontal Stabilizer
Leading edge
O 1 Check surface for erosion, scratches, stone nicks and impact damage.
O 2 Check bonding top/bottom for dents, cracks and delamination.
Front spar section
Rear spar section
Spar carry-through
O 5 Remove spar cap paint by a solvent. Perform visual inspection for dents
and cracks. Check for delamination by coin tapping. Restore finish in
O 6 Remove Spar web paint using an appropriate solvent. Perform visual
inspection for dents and cracks. Check for delaminations by coin
tapping. Restore finish in accordance with Chapter 51-70-05.
O 7 Replace attachment bolts and stop nuts. Check for proper torque in
O 8 Check steel sleeves for secure bonding to the spar.
Root and Tip
O 9 Check root rib for cracks, delamination and secure bonding to skin and
spars by coin tapping.
Elevator
O 1 Check tip rib bonding to the skin laminate by coin tapping.
O 2 Check bonding skin/spar for delaminations by coin tapping.
O 3 Check bonding trailing edge for cracks and delamination by coin
tapping.
O 4 Detailed visual inspection of mounting brackets for damage, cracks
and proper attachment. Replace bolts and stop nuts. Check for proper
torque in accordance with Chapter 20-10-02.
O 5 Check center section for delamination by coin tapping.
PAGE DATE:
PAGE DATE:16.
15.January
December
20091999 CHAPTER 05
PAGE 32
s Date: Inspector:
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0 Serial No.:
0
10 Inspections
O 6 Detailed visual of actuator lever for damage, cracks and proper attach-
ment.
O 7 Detailed visual of mass balance attachment and mounting boom for
deformation, corrosion and cracks.
O 8 Detailed visual of trim tab hinges, actuator lever for damage, cracks,
excessive wear and proper bonding to the laminate. Detailed visual for
delamination.
O 9 Inspect ventilation holes for obstruction.
Surface general
O 10 Check painting for general condition (blisters etc.).
O 11 Check laminate for erosion, scratches, stone nicks and impact dam-
ages.
Fuselage
O 1 Inspect tubular steel frame visually for corrosion, scratches and
damages.
O 2 Check wing main spar attachment for damage and corrosion. Inspect
for dents and cracks.
O 3 Detailed visual of the sheet metal of the wing auxiliary spar attachment
for damage, corrosion. Inspect the sheet metal supports using a
fluorescent dye penetrant to insure no cracks are evident.
O 4 Detailed visual of cockpit frame visually for dents, cracks and
delaminations.
O 5 Inspect main fuselage cover visually for dents, cracks and delamination.
Flight controls
O 1 Detailed visual of torque tube for damages, cracks, free-play and stop
adjustments.
O 2 Detailed visual of bell cranks for damage, cracks, corrosion, security
of mounting and link bolts.
O 3 Inspect control rods for loose or popped rivets and general condition.
O 4 Inspect sticks (rear & front) for full travel, proper rigging, free-play,
security of mounting and direction of control surface movement with
relation to stick movement.
O 5 Check rod end bearings for free movement and cleanliness.

PAGE 33
s Date: Inspector:
r
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0 Serial No.:
0
10 Inspections
O 6 Detailed visual of trim actuator lever for damages and cracks. Ensure
proper attachment and condition of friction.
Main landing gear
O 1 Inspect landing gear spring visually for dents, cracks and delaminations,
especally at the axle attachment and the center bushing for wear and
looseness.
O 2 Check mounting clamp for damage and corrosion. Inspect for dents and
cracks.
O 3 Inspect mounting clamp bolts and nuts for fretting, wear, damage,
stretch and proper torque (refer to Chapter 20-10-03).
O 4 Check brakes discs for warping and wear. Inspect wheel brake cylinder
mounting brucket for wear.
O 5 Inspect brake lines for leakage, dents, cracks, chaffing, kinks and
security of anchorage.
O 6 Inspect axle attachment bolts and nuts for fretting, wear, damage, and
stretch.
O 7 Check tires for general condition.
Tail-wheel landing gear
O 1 Inspect glass fibre spring visually for dents, cracks and delaminations.
O 2 Inspect mounting bolts and nuts for fretting, wear, damage, stretch and
proper torque.
Standard: Full-swivel tail-wheel
O 1 Check tail-wheel for free rotation and general condition.
O 2 Inspect swivel arm visually for damage, dents, cracks and corrosion.
Check for swivel feature.
O 3 Inspect axle bolt and nut for fretting, wear, damage, and stretch.
O 4 Check rubber tire for general condition.
Optional: Steerable tail-wheel
O 1 Check tail-wheel for general condition and function. Pay attention to
the free movement of the rudder.
O 2 Check connector springs for light precompression.

PAGE 34
s Date: Inspector:
r
hou Mechanic:
0 Serial No.:
0
10 Inspections
O 3 Inspect wheelfork visually for damage, dents, cracks and corrosion.

O 4 Inspect axle bolt and nut for fretting, wear, damage, and stretch.
O 5 Check rubber tire for general condition.
Engine compartment
O 1 Check firewall for dents, cracks and deformation.Visual inspection of
silicon seals for porosity and general condition.
O 2 Inspect tubular engine mount for dents, cracks and corrosion. Check all
bolts for security and condition.
O 3 Visual inspection of rubber mounts (shock mounts) for porosity and
general condition.
O 4 Inspect flexible hose for damage and leakage.
O 5 Visual inspection of fire sleeves for chaffing and general condition.
O 6 Check electric wiring for proper connection.
O 7 Check grounding straps for proper connection.
O 8 Visual inspection of inverted oil system for general condition accord-
ing to CHRISTEN 801instruction. Refer to CHRISTEN Product Manual
or to the applicable TEXTRON LYCOMING Operator`s or Maintenance
Manual (refer to Chapter 01).
O 9 Carry out general engine check as instructed by the applicable
TEXTRON LYCOMING Operator`s or Maintance Manual (refer to
Chapter 01).
O 10 Visual inspection of cowling for dents,cracks,delamination and smoke
marks.
Hardware
O 1 Magnaflux or fluorescent dye-check of the wing main spar bolts by
authorized personnel is required. (Remove only one bolt at a time).
Inspect for security of the spar bolts and safety-screws.
O 2 Check harness attachment fittings for cracks, deformations and
corrosion.
O 3 Check bolts and nuts in critical areas for fretting, wear, damage, stretch,
proper torque and safety.
O 4 Visual inspection of center tank fastening straps for cracks, damage and
corrosion.

PAGE 35
s Date: Inspector:
r
hou Mechanic:
0 Serial No.:
0
10 Inspections
O 5 Visual inspection of battery fastening straps for cracks, damage and

corrosion.
O 6 Check the "quick pins" of the seat adjustment for cracks, deformations
and corrosion. Inspect wear and proper function.
O 7 Visual inspection of rudder pedal mounting to the attachment fittings.
Check bolts for security.
Surface general
O Visual check of painting for deteriorated paint.

PAGE 36
EXTRA
05-50-00 UNSCHEDULED MAINTENANCE

CHECKS
Unscheduled checks are only performed after abnormal

events, which could possibly have caused damage to the
aircraft or impaired the airworthiness.
I M PO R TAN T In case of abnormal events or any exceedance of given

limitations (load factor, never exceed speed, etc.) the
manufacturer has to be contacted to find appropriate
maintenance procedures. Therefore the procedures de-
scribed in the following could be subjected to changes.
05-50-01 Violent Stopping of the Engine (Propeller

Strike)
In a case where the propeller has struck the ground or the

engine has been stopped violently (shock loading), the com-
plete engine has to be disassembled and checked by an
authorized company. The crankshaft might be damaged. The
propeller has to be checked and repaired by an authorized
company according to MT-propeller instruction. Refer to
MT-propeller "Operation- and Installation Manual E-124".
05-50-02 Hard Landing
After an extremely hard landing or other unusual loads on the

landing gear, perform a check as described in the following,
even when there are no obvious signs of damage: If there are
indications that structural parts are damaged, the manufacturer
has to be consulted for possible and suitable repair methods.

PAGE 37
EXTRA UNSCHEDULED MAINTENANCE CHECKS
SERVICE MANUAL EXTRA 300L Hard Landing
Date: Inspector:
Serial No.: Mechanic:
Inspections
Landing gear
O 1 Examine landing gear mounting clamps for defects (e.g. cracks and
deformed areas)
O 2 Check clamp bolts of the landing gear for cracks, replace when
necessary
O 3 Examine wheel track and check if measurement correspond to the
value given in Chapter 06-10-01.
O 4 Remove and check the fairings for delamination, deformations and
cracks
O 5 Check the landing gear spring for delamination, deformations and
cracks, especially in the area of the axle attachment
O 6 Check fuselage structure in the area of landing gear attachment for
deformation and cracks
O 7 Examine wheel base and check if measurement correspond to the value
given in Chapter 06-10-01.
O 8 Check tires for cuts in the side wall
O 9 Check wheel halves and brake discs for impacts, cracks and distortion
according to CLEVELAND instruction.
O 10 Check tail wheel for deformation and cracks, especially in the area of
the axle attachment
O 11 Check fuselage structure in the area of the tail wheel for deformation
and cracks
Control surfaces
O 12 Check control surfaces for proper operation
O 13 Check control surface hinges for cracks, security and free movement
O 14 Check the balance weights of the elevator for security of attachment
O 15 Check the spades for security of attachment
Engine
O 1 Check engine mount

PAGE 38
05-50-03 Engine Fire
After an engine fire, perform a check as described in the

following:
For damage evaluation consult the manufacturer, before the

aircraft is put back into service.
Date: Inspector:
Inspections
O 1 Check all cables and hoses, replace when necessary

O 2 Check engine according to the Lycoming Manual
O 3 Check fire wall and engine cowling for damage by high temperatures
(e.g. signs of blister on the protective paint) If necessary repaint the
fire protection paint ("WIEDOFLUGAT" Brandschutzfarbe N 56582 /
T508) .
05-50-04 Lightning Strike
In the event of a lightning strike in flight or on ground check

the following:
Date: Inspector:
Inspections
O 1 Check engine according to Lycoming Service Bulletin 401.

O 2 Check the skin of the strike area for burns and melting
O 3 Inspect bolts and fasteneners for burns and melting .
O 4 Check the electrical system, with running engine, for correct opera-
tion.
O 5 Check the avionic and antenna for correct operation.
O 6 Check the magnetic compass for correct readings.

PAGE 39
05-50-05 Flightline Inspections
These checks include pre-flight and postflight checks, as

they are described in Sections 3 and 4 ("EMERGENCY
PROCEDURES" and "NORMAL PROCEDURES") of the
PILOT´S OPERATING HANDBOOK. When the aircraft is
in operation, perform these checks daily.

PAGE 40
EXTRA
Chapter 06
Dimensions and Areas

PAGE 1
EXTRA Chapter 06
Table of Contents
Chapter Title
06-00-00 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
06-10-00 MAIN DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

06-10-01 Main Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
06-10-02 Wing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
06-10-03 Horizontal Tail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
06-10-04 Elevator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
06-10-05 Vertical Tail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
06-10-06 Rudder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

PAGE 2
EXTRA
06-00-00 GENERAL
The for measuring and weighing the aircraft relevant refer-

ence planes are the following:
Reference Planes
Plane of upper longerons (horizontal plane)

Plane of rudder (Vertical/symmetry plane)
Fire wall plane (Vertical plane)
The following figure1shows the aircraft planes :
Axes and Planes

Figure 1
Unless otherwise stated, all measurements given in this

manual are in metric (additional in feet) and are measured
parallel to the corresponding reference planes.

PAGE 3
EXTRA
06-10-00 MAIN DATA
06-10-01 Main Dimensions

(Refer to Figure 2 on page 6)
Length: 6,96 m (22,83 ft)
Height 1: 2.62 m (8.60 ft)
Height 1
Height 2 : 2.59 m (8.45 ft)
Height 2
Span: 8.00 m (26.25 ft)

Wheelbase: 5.00 m (16.40 ft)
Wheel-track: 1.80 m (5.91 ft)
MTOW: Normal category 950 kg
Acro (1 seat) 820 kg
Acro (2 seats) 870 kg
06-10-02 Wing
Span: 8.0 m (26.25 ft)

Area: 10.7 m² (115.17 ft²)
Airfoil: Root: MA 15 S. Tip: MA 12 S
Chord: Root: 1.85 m. Tip: 0.87 m
MAC: 1.404 m ( 4.61 ft)
Aileron area: 2 x 0.855 m² (2 x 9.20 ft²)
Aileron deflection: ± 30°, tolerance ± 2°

PAGE 4
EXTRA MAIN DATA
06-10-03 Horizontal Tail
Span: 3.20 m (10.50 ft)

Area: 2.56 m² (27.56 ft²)
Airfoil: Wortmann FX 71-L-150/30
06-10-04 Elevator
Area: 0.77 m² (8.29 ft²)

Elevator-deflection: up -25°, down +25°, tolerance ± 2°
Trim-tab-deflection: up -40°, down +50°, tolerance ± 5°
06-10-05 Vertical Tail
Area: 1.39 m² (14.96 ft²)

Airfoil: Wortmann FX 71-L-150/30
06-10-06 Rudder
Area: 0.51 m² ( 5.49 ft²)

Rudder deflection: left +30°, right -30°, tolerance ± 2°
PAGE 1. June
PAGE DATE: 16. 1995
PAGE 5
EXTRA MAIN DATA
Three-View EXTRA 300L

Figure 2

PAGE 6
Chapter 07
Lifting and Shoring

PAGE 1
EXTRA - FLUGZEUGBAU GmbH Chapter 07
Table of Contents
Chapter Title
07-10-00 JACKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
07-10-01 Balance Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
07-20-00 SHORING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
07-20-01 Shoring the Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
07-20-02 Shoring the Tail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

PAGE 2
07-10-00 JACKING
07-10-01 Balance Weight
Prior to the removal of the horizontal and/or vertical

stabilizer(s) or prior to shoring the aircraft as described in
Chapter 07-20-00 it is necessary to weight the tail to prevent
aircraft from tilting onto the nose. In this case follow the
steps described below (refer to Figure 1):
1 Put a weight (1) of min. 30 kg under the tail.
2 Remove the RH tail side skin and the tail cone access
panel per Chapter 51.
3 Connect the weight with the now accessible steel tube
(3) by means of a strap (2). Prevent damage of paint and
control cables.
Balance Weight
Figure 1

PAGE 3
07-20-00 SHORING
Shoring the Extra 300L is necessary, when the main landing

gear or the tail wheel has to be removed or installed.
07-20-01 Shoring the Front
1 Remove the fore access panels up to aft the main landing

gear as per Chapter 51-00-01.
2 Install a balance weight (3, Figure) at the tail as per Chapter
07-10-01.
3 Hoist the aircraft by means of both engine hoisting points
(1).
CAUT I O N Prevent damage of ventilation tubing, brake lines and

drains, when shoring the aircraft.
4 Shore the aircraft by means of two supports (2), which

are to put under the left and right bottom longeron each
in the area behind the landing gear as shown in Figure 2.
This is possible also, when the landing gear is installed.
WAR N I N G Maintain hoisting strap as a security device to prevent

nose over of the aircraft during maintenance work.
Shoring the Front

Figure 2
PAGE
PAGE DATE:
DATE: 1.
1. June
June 1995
1996 CHAPTER 07
PAGE 4
EXTRA - FLUGZEUGBAU GmbH SHORING
07-20-02 Shoring the Tail
Refer to Figure 3.
1 Secure the main wheels with wheel chocks.
2 Make available two ca. 2.5 feet high, ca. 1 foot wide and
ca. 3 feet long supports.
3 Cushion the supports.
CAUT I O N Don´t handle the elevator when lifting the tail.
WAR N I N G Do not lift the tail higher than necessary for support-
ing. The aircraft may tilt onto the nose.
4 Lift the tail some centimeters by handling carefully the

horizontal fins and put the cushioned supports under
each side of the horizontal stabilizer.
Shoring the Tail

Figure 3

PAGE 5
Chapter 08
Leveling and Weighing

PAGE 1
Table of Contents
Chapter Title
08-00-00 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
08-10-00 WEIGHING AND

CALCULATION OF C OF G . . . . . . . . . . . . . . . . . . . 4
08-20-00 LEVELING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

PAGE 2
08-00-00 GENERAL
This chapter contains all information and procedures that are

necessary for weighing and leveling the EXTRA 300L and
for determining the Center of Gravity.
Weigh the aircraft and determine the Center of Gravity each
5 years, after installation of additional equipment or after
repairs.
I M PO R TAN T Weigh, read the scales and calculate with carefulness.

Incorrect weighing or determination of Center of Grav-
ity endanger the pilot and the aircraft.

PAGE 3
08-10-00 WEIGHING AND

CALCULATION OF C OF G
NOTE Weigh the aircraft only on even floor and in closed halls
(wind protected). Use three identical scales.
1 Ensure that the aircraft is fully equipped with equipment

in locations according to the equipment list (PILOT´S
OPERATING HANDBOOK & FLIGHT MANUAL
(POH&FM), Section 6.6).
2 Defuel the aircraft (wing tanks, center and acro tank) to
the unusable fuel level.
3 Replenish engine oil to the minimum sump capacity for
acrobatic flight (refer to POH&FM Section 1.7)
4 Remove foreign objects (e.g. tools, luggage).
5 Clean and dry the aircraft.
6 Put the rear seat to middle position and close canopy.
7 Weigh two of those wheel chocks that will be used for
securing the main wheels. Enter the weight below in
Page 5 "Tare weight scale 1/2 (chocks)".
8 Weigh the jack that will be used for jacking the tail wheel.
Enter the weight below in Page 5 "Tare weight scale 3
(jack)".
9 Roll the main wheels onto the scales 1 and 2.
10 Level the aircraft as per ch. 08-20-00.
11 Put the control surfaces to neutral position.
12 Drop perpendiculars from the underside of the fire wall,
the centers of the main wheels and the tail wheel and
mark on the floor to get the arms X1 and X2 (see Page 6).
13 Enter the arms on page 6.
14 Read the scales and enter the weights below. Calculate
the net weights and transfer the values to Page 6.
15 Calculate C of G using the formula given below (Page 6).

PAGE 4
EXTRA - FLUGZEUGBAU GmbH WEIGHING
Gross weight scale 1 . . . . . . . . kg

Tare weight scale 1 (chocks) –. . . . . . . . kg
Net weight scale 1 (W1) . . . . . . . . . kg

Tare weight scale 2 (chocks) –. . . . . . . . kg

Tare weight scale 3 (jack) –. . . . . . . . kg

PAGE 5
EXTRA - FLUGZEUGBAU GmbH WEIGHING
Empty Weight and Center of Gravity Position

EXTRA 300L
Data according to "TC Data-Sheet" and "Pilot´s Operating Handbook and LBA approved
Airplane Flight Manual" Doc.-No.: EA - 06701
Equipment according to Equipment List dated: . . . . . . . . . . . .
Legend:
X1 = Arm: fire wall - main wheels
X2 = Arm: fire wall - tail wheel
XG = Arm: fire wall - Center of Gravity
W 1 = Net weight main wheel LH
W 2 = Net weight main wheel RH
W 3 = Net weight tail wheel
W = Empty weight
W1 . X1 + W2 . X1 + W3 . X2
XG = W = W1 + W2 + W3
W
Item Weight Arm Moment
Main wheel LH (W1) . . . . . . . . kg . (X1) . . . . . . . . cm = . . . . . . . . . . kgcm

Main wheel RH (W2) . . . . . . . . kg . (X1) . . . . . . . . cm = . . . . . . . . . . kgcm
Tail wheel (W3) . . . . . . . . kg . (X2) . . . . . . . . cm = . . . . . . . . . . kgcm
Empty weight (W) . . . . . . . . kg Total moment . . . . . . . . . . . . . . kgcm
Total moment
= XG
Empty weight
Empty weight is (W) . . . . . . . . . . kg*. Wmin: 640kg
Wmax: 665kg (acro II)
Wmax: 701kg (acro I)
Wmax: 745kg (Normal Cat.)
Center of Gravity is (XG) . . . . . . . . . . cm aft fire wall.
Weighing performed by: ..............
Aircraft Inspector: .............. Sign: . . . . . . . . . . . . . .
* If value exceeds the given tolerances, contact the manufacturer.

PAGE 6
08-20-00 LEVELING
NOTE Level the aircraft only on even floor and in closed halls
(wind protected).
1 Secure each main wheel with two wheel chocks.
WAR N I N G Do not lift tail wheel higher than necessary for leveling.
The aircraft may tilt onto the nose.
CAUT I O N Prior to levelling, ensure aircraft is clear of obstruc-

tions.
2 Lift tail and put the jack (height: ~90 cm (~3 ft)) under
the tail wheel, which has to be in the rearmost position.
3 Level the aircraft to its horizontal reference line using
a spirit level (2), which is to put under the bolts of the
rear main fuselage cover (1, Figure 1). Adjust pitch by
changing the jack height.
Leveling
Figure 1

PAGE 7
Chapter 09
Towing and Taxiing

PAGE 1
Table of Contents
Chapter Title
09-00-00 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
09-10-00 TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
09-20-00 TAXING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

PAGE 2
09-00-00 GENERAL
This chapter describes the procedures and precautions

nescessary for proper ground handling of the EXTRA 300L.
09-10-00 TOWING
DAN GE R When preparing for ground handling operation ensure

that the ignition switch is off.
The aircraft should be moved on the ground by hand without

using a towing vehicle or tow bar. For moving the aircraft on
the ground, push by hand the wing leading edges or pull at the
inboard portion of the propeller blades.
09-20-00 TAXING
Before attempting to warmup or taxi the aircraft, ground

personnel should be checked by qualified pilots or other
responsible personnel. All taxiing should be done at slow
speed, and the controls should be positioned such that the
effects of gusty wind are minimized.
CAUT I O N Taxiing over loose gravel or cinders should be done at

low engine speed to minimize damage to the airframe
surfaces due to stone damage.
The aircraft is taxiing as follows:

1 Start and warm engine up in accordance with the Pilot´s
Operating Handbook (PN: EA-06701) Section 4.3 "Start-
ing Procedures".
CAUT I O N Only operate with the propeller at minimum blade an-

gle (High RPM).
2 Taxi forward a few feet and check brake effectiveness.

PAGE 3
EXTRA - FLUGZEUGBAU GmbH TOWING AND TAXING
3 While taxiing, make shallow turns to test the brakes and

the steerable tail wheel if installed.
4 Keep the Mixture in "FULL RICH" position.

PAGE 4
Chapter 10
Parking, Mooring, Storage and Return to Service

PAGE 1
Table of Contents
Chapter Title
10-00-00 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
10-10-00 PARKING / STORAGE . . . . . . . . . . . . . . . . . . . . . . . . 4
10-20-00 MOORING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
10-30-00 RETURN TO SERVICE . . . . . . . . . . . . . . . . . . . . . . . . 6

PAGE 2
10-00-00 GENERAL
This chapter provides the procedures recommended to park

or to moor the aircraft so that the likelihood of ground
damage is minimized.

PAGE 3
10-10-00 PARKING / STORAGE
When parking the aircraft, set the nose in the wind. Addition-
ally both main wheels must be chocked fore and aft to
prevent movement of the aircraft.
CAUT I O N When chocking the wheels, ensure that the chocks used
are not too large to come in contact with the wheel
farings. The use of chocks that are too large may dam-
age the farings.
NOTE For maximum protection, hangar the aircraft during

severe weather and strong winds.
The outdoor storage requires adequate mooring and tie-

down facilities. The following precautionary measures are
recommended for keeping the aircraft serviceable and ready-
to-fly.
1. Refer to Chapter 10-20-00 "Mooring" for mooring
instructions.
DAN GE R Do not rotate the propeller with the master switch on

and the battery connected. The engine could start
unintenionally and may course serious injuries or
death.
2. Maintain an oil film on internal engine parts, frequently

pull the propeller through. Run the engine for 15 min-
utes at 1500 RPM (or until oil temperature normalizes)
once every two weeks.
3. After the engine run, pressurize the fuel system, push the
mixturecontrol to RICH, and open throttel half way to
fill the fuel injector with fuel.
4. Install protective covers over pitot tube, engine cowling
openings, canopy, etc.
5. Maintain a good wax finish on all exterior surfaces.

PAGE 4
10-20-00 MOORING
This section provides the procedures recommended for a

normal tie-down of the aircraft.
Proper tie-down procedure is the best precaution against
damage to the aircraft by gusty or strong winds. To tie-down
the aircraft securely, proceed as follows:
1. Head the aircraft into the wind
2. Place chocks fore and aft of each main wheel.
When chocking the wheels, ensure that the chocks used

are not too large to come in contact with the wheel
farings. The use of chocks that are too large may damage
the farings.
3. Drive stakes into the ground approximately three feet

outboard of each wing tip and to either side of tail wheel.
4. Install one tie-down ring in each wing tip rib.
5. Tie a sufficiently strong rope to each wing tie-down ring
and anchor to the ground stakes. Allow a little slack in
each tiedown rope.
6. Tie the center of the rope to the tail wheel fork and an-
chor the rope ends to the ground stakes at either side of
the tail wheel.
7. Ensure that the canopy is closed waterproof and locked.

PAGE 5
10-30-00 RETURN TO SERVICE
If the aircraft has been storage for an extended period of

time, it is advisable to perform a 50-hour periodic inspec-
tion. Refer to Chapter "05-20-04 Scheduled Maintenance
Checks" .

PAGE 6
EXTRA
Chapter 12
Servicing
PAGE DATE: 16.

1. June
January
1995
2009 CHAPTER 12
PAGE 1
EXTRA
Table of Contents
Chapter Title
12-00-00 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
12-10-00 REPLENISHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
12-10-01 Refueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
12-10-02 Defueling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
12-10-03 Fuel Drains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
12-10-04 Replenishment of Engine Oil. . . . . . . . . . . . . . . . . . . . . 6
12-10-05 Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
12-10-06 Replenishment of Brake Fluid . . . . . . . . . . . . . . . . . . . 11
12-10-07 Tire Inflation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
12-20-00 SCHEDULED SERVICING . . . . . . . . . . . . . . . . . . . 14

12-20-01 Exterior Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
12-20-02 Interior Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
12-20-03 Engine Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
12-30-00 UNSCHEDULED SERVICING . . . . . . . . . . . . . . . . . 17

12-30-01 Removal of Snow and Ice. . . . . . . . . . . . . . . . . . . . . . . 17
PAGE
PAGE DATE: 16.
1. June
January
19952009 CHAPTER 12
PAGE 2
EXTRA
12-00-00 GENERAL
This chapter describes the procedures and precautions

nescessary for proper servicing of the EXTRA 300L. The
specified intervals (refer to chapter 5) are considered
adequate to meet average requirements under normal oper-
ating conditions.
It is advisable, however, to shorten service and maintenance
intervals when operating under abnormal conditions, such as
extreme temperature ranges, dusty atmospheric conditions,
high humidity and moisture, unimproved airport facilities,
or unusual operating requirements.
PAGE DATE: 16.

1. June
January
1995
2009 CHAPTER 12
PAGE 3
EXTRA
12-10-00 REPLENISHING
The replenishing procedures contained in this section pro-

vide the proper methods for replenishing consumed fuel,
engine oil and brake fluid. Also included are methods for
inflation of tires.
12-10-01 Refueling
Refueling is accomplished by pumping or pouring fuel into

the two wing tanks and the center tank through their respec-
tive filler caps. When fueling the aircraft, the following
safety precautions must be followed:
D AN G E R * Never refuel the aircraft with the engine running.
* Always ensure that the aircraft is grounded before

refueling.
* Ensure that no one is smoking within 100 feet of the
aircraft.
* Ensure that all aircraft electrical systems are
deenergized while refueling.
* Ensure that no aircraft radar or powerful transmit-
ters are operating within 100 feet of the aircraft dur-
ing fueling.
* If fuel is spilled, ensure that the area of spillage is
thoroughly flushed with water and that all residual
fuel and vapor have dissipated or neutralized prior
to starting the aircraft engine.
Fuel Grade and Limitations
The recommended minimum aviation grade fuel for the

AEIO-540-L1B5 and AEIO-580-B1A engine is AVGAS 100
or 100LL.
PAGE DATE:
DATE: 16.
1. June
January
1995
2009 CHAPTER 12
PAGE 4
EXTRA REPLENISHING
SERVICE MANUAL EXTRA 300L Refueling
I M PO RTANT Under no circumstances should fuel of lower octane rat-

ing or automotive fuel (regardless of octane rating) be
used. It is recommended that personnel be familiar
with Service Instruction No.1070 regarding specified
fuel for Lycoming engines.
Fuel System Capacities
Configuration 1 (with 42 L Center tank):

Wing tank LH 60 L (15.8 US Gallons)
Wing tank RH 60 L (15.8 US Gallons)
Center and acro tank 51 L (13.5 US Gallons)
Total fuel capacity 171 L (45.1 US Gallons).
Usable fuel capacity 165.5 L (43.6 US Gallons).
Usable fuel capacity
for acrobatic 45.5 L (12 US Gallon).
Configuration 2 (with 60 L Center tank):

Wing tank LH 60 L (15.8 US Gallons)
Wing tank RH 60 L (15.8 US Gallons)
Center and acro tank 69 L (18.2 US Gallons)
Total fuel capacity 189 L (49.9 US Gallons).
Usable fuel capacity 187 L (49.4 US Gallons).
Usable fuel capacity
for acrobatic 67 L (17.7 US Gallon).
I M PO RTANT For acrobatic flight wing tanks must be empty.
I M PO RTANT After refueling, it has to be ensured that both fuel tank

caps are securely installed pior to flight.
Additionally one has to wait at least five minutes for mois-

ture and sediment to settle before draining and checking the
fuel drain valves.
PAGE
PAGE DATE: 16.
1. June
January
19952009 CHAPTER 12
PAGE 5
EXTRA REPLENISHING
12-10-02 Defueling
DAN GE R During the aircraft defueling observe the safety pre-

cautions specified in section "12-10-01 Refueling".
Using appropriate containers, defuel the aircraft by pumping

or by siphoning off fuel through the filler ports (only for the
wing tanks) and by opening the gascolator and center tank
drain valves.
12-10-03 Fuel Drains
The EXTRA 300L has three fuel drain valves to provide for
drainage of moisture and sediment. Two fuel drain valves are
located under the fuselage in the area of the landing gear; the
third fuel drain which is interconnectecd to the fuel gascolator
is located in the lowest point at the right side of the firewall.
DAN GE R Do not drain the fuel system when the engine or the
exhaust is hot or while the wind is strong.
A quantity of fuel must be drained prior to the first flight of

the day and at least five min. after refueling to inspect for
water and/or contamination. Continue draining until free of
water or contamination.
I M PO RTANT After draining, you have to be sure that the fuel drain
valve is returned to the closed position and the valve
is not leaking outside the aircraft.
12-10-04 Replenishment of Engine Oil
The engine oil replenishment is accomplishment by pouring

oil into the oil filler spout. The oil quantity can be conveniently
checked by use of the dipstick attached to the oil filler spout
cap.
PAGE DATE: 16.

1. June 1995
PAGE 6
EXTRA REPLENISHING
SERVICE MANUAL EXTRA 300L Replenishment of Engine Oil
Oil quantity
The oil quantity is checked as follows:

1 Check oil level after engine has been stopped long enough
for oil to drain back into sump.
2 Open the hatch on the upper part of the cowling.
3 Unsrew oil filler cap and dipstick from engine oil filler
spout.
4 Remove cap and dipstick from engine and wipe oil from
dipstick with a clean cloth or paper towel.
5 Return dipstick into filler spout and tighten finger tight.
6 Unsrew and remove dipstick. Check oil level on dipstick
versus the markings stamped on the dipstick.
7 If replenishment is required see "Replenishment of En-
gine Oil" below.
8 Return dipstick into filler spout and tighten cap finger
tight.
CAU T I O N When tightening the filler spout cap ensure that is se-
cure. But do not overtighten, as this may damage the
"O" ring seal in the cap.
9 Close the hatch on the upper part of the cowling.
Replenish engine oil
Replenish engine oil using oil of the following specifica-

tion:
Aviation Grade Straight Mineral oil
MIL-L-6082 or SAE J1966 Aviation Grade Straight Mineral

oil shall be used to replenish oil supply during the first 25
hours of operation and at the first 25-hour oil change.
Continue to use this grade of oil the first 50 hours of
operation or until oil consumption has stabilized. The
aircraft is delivered from EXTRA-Flugzeugproduktions-
und Vertriebs GmbH with proper break-in oil (MIL-L-6082
Aviation Grade Straight Mineral oil ).
PAGE DATE:
DATE:16.
1. January
June 1995
2009 CHAPTER 12
PAGE 7
EXTRA REPLENISHING
Ashless Dispersant Oil
MIL-L-22851 or SAE J1899 Ashless Dispersant Oil shall be

used after the first 50 hours of the engine operation.
Additive Oil
If an engine has been operating on straight mineral oil for

several hundred hours, a change to additive oil should be
undertaken with caution. If the engine is in an extremely dirty
condition, the switch to additive oil should be deferred until
after engine has been overhauled.
When changing from straight mineral oil to additive oil take
the following precautionary steps:
I M PO RTANT 1 Do not mix additive oil and straight mineral oil.

Drain straight mineral oil from engine and fill with
additive oil.
2 Do not operate engine longer than five hours before
again changing oil.
3 Check oil screen for evidence of sludge.
Change oil and clean oil screen element every 10 hours if
sludge is evident. Resume normal oil drain periods after
sludge conditions improve.
PAGE DATE: 16.

1. June
January
1995
2009 CHAPTER 12
PAGE 8
EXTRA REPLENISHING
Recommended Viscosity of Engine Oil:
MIL-L-6082 or MIL-L-22851 or
Average Ambient SAE J1966 Spec. SAE J1899 Spec.
Air Temperature Mineral Grades Ashless Dispersant
Grades
All Temperature ---------- SAE 15W50 or

SAE 20W50
Above 27°C (80°F) SAE 60 SAE 60
Above 16°C (60°F) SAE 50 SAE 40 or SAE 50
-1°C (30°F) to 32°C (90°F) SAE 40 SAE 40
-18°C (0°F) to 21°C (70°F) SAE 30 SAE 30, SAE 40 or

SAE 20W40
-18°C (0°F) to 32°C (90°F) SAE 20W50 SAE 20W50 or

SAE 15W50
Below -12°C (10°F) SAE 20 SAE 30 or SAE

20W30
NOTE Refer to latest revision of Lycoming Service Instruc-

tion No. 1014 for further information.
Replenish engine oil as follows:

1 Open the hatch on the upper part of the cowling and
unsrew oil filler cap.
2 Using a clean paper towel wipe any oil foreign material
from the edges of the filler spout opening. Also wipe oil
from the dipstick.
3 Pour oil of proper specification and viscosity into filler
spout to achieve desired oil level.
4 Replace oil filler spout cap/dipstick and tighten finger
tight. Close the hatch on the upper part of the cowling
and secure engine cowling.
PAGE DATE: 16.

1. June
January
1995
2009 CHAPTER 12
PAGE 9
EXTRA REPLENISHING
SERVICE MANUAL EXTRA 300L Oil Change
Oil System Capacities:
12-10-05 Oil Change
The engine oil must be changed after 25 hours of operation.

It should be refilled in accordance with section "12-10-04
Engine Oil Replenishing" and the latest revision of Lycoming
Service Instruction No. 1014.
At the time of each oil change the engine oil screen at the
engine should be removed, cleaned, and inspected for metal
particles.
Change engine oil as follows:
1 Remove the cowling of the aircraft.
2 Remove the exhaust port of the second engine
cylinder (for easy access to the oil drain).
3 Cut the safety wire securing the oil drain plug.
4 Place a suitable container under the oil drain.
5 Unscrew engine oil drain plug and allow the oil to drain
thoroughly.
6 Remove the oil temp. sensor carefully. Do not cut the
wire.
7 Remove remaining safety wire from drain plug and
safety wire hole on engine.
8 Using a clean rag or paper towel, wipe drain plug clean
and area on engine around oil drain.
9 Reinstall drain plug and safety wire.
PAGE DATE: 16.

1. June
January
1995
2009 CHAPTER 12
PAGE 10
EXTRA REPLENISHING
SERVICE MANUAL EXTRA 300L Replenishment of Brake Fluid
10 Remove, clean, inspect and reinstall engine oil strain-

ers in accordance with Lycoming Operating Manual.
11 Reinstall oil temp. sensor.
12 Replenish engine oil as per Chapter 12-10-04.
13 Reinstall the exhaust port of the second cylinder using
new sealing rings.
14 Reinstall and secure the cowling.
12-10-06 Replenishment of Brake Fluid
In order to assure proper brake action, it is necessary to have

positive transfer of hydraulic pressure through the system.
Any air trapped in the system must be removed. Follow the
procedure described below using a bleed tank (1, Figure 1):
1 Remove engine cowlings (Up to serial No. 02 the brake
fluid reservoir is installed at the cockpit side of the
firewall. So in those cases the main fuselage cover has
to be removed too.) as per Chapter 51-00-01.
2 Remove fluid reservoir filler plug and screw a clear plas-
tic hose with appropirate fitting into the filler hole at
the top of the fluid reservoir.
3 Remove bleeder fitting cap (3) of the wheel brake as-
sembly (2).
PAGE DATE:
DATE:16.
1. January
June 1995
2009 CHAPTER 12
PAGE 11
EXTRA REPLENISHING
SERVICE MANUAL EXTRA 300L Replenishment of Brake Fluid
Replenishment of Brake Fluid

Figure 1
4 Be certain that the bleeding equipment to be used is ab-

solutely clean and is filled with brake fluid that con-
forms to Specification MIL-H-5606, (refer to Chapter
05-20 Lubrication Charts) and is uncontaminated.
5 Maintain an adequate supply of fluid during the entire
operation. A low fluid supply will allow air to be drawn
into the system.
6 Ensure master cylinders are in neutral position.
7 Attach the connector hose (4) to the bleeder fitting.
8 Turn the bleeder fitting 1/2 rotation to the left for open-
ing.
9 Slowly pump clean hydraulic fluid in the system. Bleed-
ing should continue until no more air bubbles are ex-
pelled from the system (observe the immersed end of
the clear hose), and a firm brake pedal is obtained (fill
each side of the system with min. 0.33 ltr (0.1 U.S
Gallons) for complete change).
10 Fill the fluid reservoir up to full reservoir capacity.
11 Reinstall fluid reservoir filler plug.
12 Close bleeder fitting.
PAGE DATE: 16.

1. June
January
1995
2009 CHAPTER 12
PAGE 12
EXTRA SCHEDULED SERVICING
13 Disconnect the connector hose.

14 Reinstall bleeder fitting cap.
15 Check the brake operation.
12-10-07 Tire Inflation
For the EXTRA 300L the required tire pressure is 3.4 bar
(49,3 Psi) for both main wheels. When inflating tires, it has
to be used regulated air pressure through valve sems.
PAGE DATE: 16.

1. June 1995
PAGE 13
SERVICE MANUAL EXTRA 300L Exterior Cleaning
12-20-00 SCHEDULED SERVICING
12-20-01 Exterior Cleaning
The painted surface of the aircraft have a long lasting, all-

weather finish and should require no buffing or rubbing out
in normal conditions. However, it is desirable to wash and
polish it to preserve the outstanding exterior. Cleaning is
best accomplished with cool water, mixed with a mild aircraft
detergent, if required.
CAU T I O N Do not use so called "mild" household detergents to

wash aircraft exterior. Such detergents may damage
finish and corrode aluminum components.
In order to remove especially heavy dirt from the wing

leading edges due to insect splatter and the like, it is good
practice to undertaken cleaning immediately after the flight,
since deposits of this kind are more difficult to remove when
dry. All lubricated components are to be covered before
cleaning.
Roughly twice a year, the complete surface should be treated
with a non-silicone car polish and repolished to high gloss.
But do not apply wax or use pre-wax cleaners during initial
paint curing period. Use only mild aircraft detergent and
cool water when washing exterior during the first 90 days
after repainting.
CAU T I O N Never use cleaning agents containing silicone!
In order to maintain good visibility at all times, the canopy

Plexiglas should begiven good care and kept clean at all
times. Techniques and materials used to clean glass should
be avoided since Plexiglas is softer than glass and subject to
damage by solvents and abrasive glass cleaning agents.
Therefore it should be pay particular attention to using ample
water applied with clean sponges and leather, otherwise even
the smallest dust partiles will tend to scratch the glazing.
CAU TI O N Never polish plexiglass dry!
PAGE DATE: 16.

1. June
January
1995
2009 CHAPTER 12
PAGE 14
SERVICE MANUAL EXTRA 300L Engine Cleaning
Dull or scratched canopy sections can be returned to their

transparent state by treating with especially formulated
plexiglass cleaning agents.
12-20-02 Interior Cleaning
Prior to the first acrobatic flight of the day it is recom-

mended to clean the interior with a vacuum cleaner to
remove dust and loose dirt. If liquid is spilled on the cockpit
floor, blot it up promptly with cleansing tissue or rags.
Continue blotting until no more liquid is taken up.
CAU T I O N Never use gasoline, benzine, alcohol, acetone, carbon

tetracloride, fire extinguisher fluid, anti-ice fluid, lac-
quer thinner, or glass cleaner to clean the canopy. These
materials will damange the canopy and may cause se-
vere crazing.
12-20-03 Engine Cleaning
Accumulation of dirt and oil within the engine compartment

creates a fire hazard and hampers inspection. All cleaning
operations have to be performed in well ventiated work
areas, and it is ensure that adequate fire-fighting and safety
equipment is avaiable.
The engine is cleaning as follows:
1 Allow the engine after running to cool before cleaning.
CAU TI O N 2 The magnetos, alternator, starter, the air inlets and

the engine cowling (the inside of the engine cowling
is covered with water soluble fire protection paint)
must be protected against cleaning agents.
3 Wash down engine compartment using a nonflammable

engine cleaning agent.
4 Thorougly rinse with clean, warm water to remove all
traces of cleaning agents.
PAGE DATE:
DATE:16.
1. January
June 1995
2009 CHAPTER 12
PAGE 15
EXTRA
5 It is very important not to start the engine before the

cleaning agent has been completely removed or has evapo-
rated.
PAGE DATE: 16.

1. June 1995
PAGE 16
EXTRA
12-30-00 UNSCHEDULED SERVICING
12-30-01 Removal of Snow and Ice
After snowfall, the snow should be removed immediately

from surface of the aircraft. Otherwise the water formed
from melted snow will freeze on the surface or in slots and
gaps of fairings.
CAU T I O N Do not use sharp tools for removing the snow.
If the aircraft shows sign of ice formation, it is recom-

mended to defrost in a room. Remove as much snow as
possible with a soft bristle boom, make sure the wheels and
brakes are clear, and tow the aircraft into a room with
elevated temperature. This method is particularly desirable,
since it will melt any undetected ice and snow that could
constitute a flight hazard.
PAGE DATE:
DATE:16.
1. January
June 1995
2009 CHAPTER 12
PAGE 17
EXTRA
Chapter 20
Standard practices - Airframe

PAGE 1
EXTRA Chapter 20
Table of Contents
Chapter Title
20-00-00 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
20-10-00 STANDARD PRACTICES AIRFRAME . . . . . . . . . . . 4

20-10-01 Type of Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
20-10-02 Width Across Flats for Metric Bolts . . . . . . . . . . . . . . . 6
20-10-03 Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
20-10-04 Special Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . 8
20-10-05 Measuring Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . 9
20-10-06 Coin Tapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
20-10-07 Flexible Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
20-10-08 Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
20-20-00 ASSEMBLY INSTRUCTION . . . . . . . . . . . . . . . . . . 12

20-20-01 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
20-20-02 Assembly Instruction after Container Shipping . . . . . . 12

PAGE 2
EXTRA
20-00-00 GENERAL
The design of the airframe is according to standard proce-

dures and requires no special tools or procedures for main-
tenance. For that reason, only the bolts used in the Extra
300L with relevant torque values and measuring techniques
are described in the following.

PAGE 3
EXTRA
20-10-00 STANDARD PRACTICES AIRFRAME
20-10-01 Type of Bolts
For the Extra 300L, LN-bolts (LN="Luftfahrt Norm"), AN-

bolts (AN="Army/Navy") and DIN-bolts (DIN="Deutsche
Industrie Norm") are used. The type of bolt can be identified
by the designation on bolt head and by the surface treatment.
LN-Bolts
Hex head LN 9037, LN 9038 K and LN 9355 aircraft bolts

are made of high-strength type 1.7220.5 alloy steel. The
bolts are centerless ground, threaded after heat treatment
and cadmium plated per specification LN 9368-3000.2.
Bolts according LN 9037 are standard aircraft bolts with
undrilled shank. The specification LN 9355 indicates bolts
with shank drilled for cotter pin. The specification LN 9038
K indicates bolts with drilled head for safety wire and a shank
up to the head.
The adding numbers after the dash of bolt spec. indicates the
dimensions of the bolt. These numbers are not marked on the
head of the LN bolt. Measure the diameter and length to
specify the type dimension of the LN bolt. The length of LN
aircraft bolt is measured from under the head to the end of
the shank.
Example: LN 9037-08042
Bolt Head Identification Metric thread size (M8=8 mm)

and Lenght (042=42mm/
1.65 inch)
Bolt Head:
Letter (R,L,P,H = Identification of
Manufacturer)
LN Specification

PAGE 4
EXTRA STANDARD
ANDARD PRACTICES AIRFRAME
SERVICE MANUAL EXTRA 300L Type of Bolts
AN-Bolts
Hex head AN aircraft bolts are made of high-strength type

4037 or 8740 alloy steel. The bolts are centerless ground,
threaded after heat treatment and cadmium plated per speci-
fication QQ-P-416A, Type II, Class 3.
For the Extra 300L bolts with shank drilled for cotter pin or
drilled head for safety wire are used. The adding letter "A"
after the dash number specifies bolts with undrilled shank.
For bolts with drilled head a letter "H" is added after the AN
number. The length of AN aircraft bolts is measured from
under the head to the end of the shank.
Example: AN 3 - 5A
Bolt Head Identification AN hex head bolt

Diameter 3/16" (4.8 mm) Length 5/8" (15.9 mm)
Undrilled shank
Letter (Identification of Manufacturer,
not always given.)
Cross (Alloy Steel)
Letter (also
adjected)
DIN-Bolts
Hex head DIN 931, DIN 933 and hex socket head DIN 912
bolts are standard bolts made of steel with undrilled shank.
The surface treatment is chromatized yellow.
Unlike the DIN 931 and DIN 912 the shank of a DIN 933 bolt
goes up to the head. The numerical code shown on the head
of a DIN bolt specifies the strength type. Also, most bolts
will bear a wide variety of finitials or symbols which identify
the manufacturer. Measure the diameter and length to specify
the type dimension of the DIN bolt. The length of DIN bolt
is measured from under the head to the end of the shank.

PAGE 5
EXTRA STANDARD
ANDARD PRACTICES AIRFRAME
SERVICE MANUAL EXTRA 300L Type of Bolts
Example: DIN 931, M10 x 80 - 8.8
Bolt Head Identification Standard hex head bolt

Metric thread size M10
Length 80mm (3.15")
Strength type 8.8
Bolt Head:
DIN 931: DIN 933:
Identification of
manufacturer (OEV)
Strength type
(8.8 resp.12.9)
20-10-02 Width Across Flats for Metric Bolts
Thread diameter Width across flats
M4 7 mm
M5 8 mm
M6 10 mm
M8 13 mm
M10 17 mm
M12 19 mm
M16 24 mm
M20 30 mm
M24 36mm

PAGE 6
EXTRA STANDARD PRACTICES AIRFRAME
20-10-03 Torque Values
Nuts, except of counter nuts are mainly stop nuts according

to LN 9348 or selflocking nuts according to AN 363.
a) Standard torque values allowed for bolts and nuts accord-
ing to DIN and LN must be adhered to as follows:
Metric thread size Torque value
(Nm) (in.lbs)
M4 1,8 16
M5 3.9-4.3 35-38
M6 6.2-6.8 55-60
M8 15.2-16.8 144-148
M10 29.5-32.5 261-287
M12x1.5 51-57 452-504
b) Standard torque values allowed for bolts and nuts according

to AN and MS must be adhered to as follows:
Inch thread size Torque value
(Nm) (in.lbs)
1/4 -28 3,5-4,5 30-40
5/16 -24 6,7-9,5 60-85
3/8 -24 10,7-12,5 95-110
7/16 -20 30,5-33,9 270-300
1/2 -20 32,8-46,3 290-410
9/16 -18 88,1-67,8 480-600
I M PO R TAN T On all bolt connections, the specified torque and lock-

ing method must be observed. Do not reuse stop nuts if
they can be run up finger tight!

PAGE 7
20-10-04 Special Torque Values
Special torque values for the following items must be adhered

to:
Torque value
Item
(Nm) (in.lbs)
Brake Back Plate Bolts (Cleveland) Refer to Cleveland
Maintenance
Wheel Assembly Bolts (Cleveland) Manual
Engine Mounting
(Bolts AN7-50A / Metal Stop Nut 55 480
NAS 363C-720)
Engine Mount to Fuselage
(Bolt Din 912, M12-12.9 / Stop Nut 80 720
DIN 985, M12-8-B2C)
Longeron Cutout Bridge
(Bolt DIN 912 M8-8.8 / Stop Nut 18 160
LN 9348-08)
Horizontal Stabilizer Front Spar
Bolts (Bolt LN 9037-10054 / Stop 33 292
Nut LN 9348-10)
Horizontal Stabilizer Rear Spar Bolts
(Bolt LN 9037-08042 / Stop Nut LN 14 124
9348-08), for S/N 1 through 93
Horizontal Stabilizer Rear Spar Bolts
9348-10), for S/N 94 following
Vertical Stabilizer Rear Spar Bolt
9348-10)
Wing Main Spar Safety-Bolts

15 133
(Bolt LN 9038 K-08020)
Torque for Engine Refer to Lycoming

Overhaul Manual
Torque for Propeller Refer to
MT-propeller
Installation Manual
E-124
I M PO R TAN T On all bolt connections, the specified torque and lock-

ing method must be observed. Do not reuse stop nuts if
they can be run up finger tight!
PAGE
PAGE DATE:
DATE: 1.
4.June
1. December
June 1995
1996 2001 CHAPTER 20
PAGE 8
20-10-05 Measuring Techniques
When using stop nuts, the safety torque (friction torque or

braking torque) should be added to the table standard values.
This value is indicated on the dial of the torquemeter, before
the nut contacts the attachment surface.
Always torque nuts for fastening, if possible. When bolts are
torqued there might be an additional torque value due to shaft
friction. This torque can be determined by a torquemeter
before the bolt head contacts the attachment surface and
should be added to the table value.
20-10-06 Coin Tapping
Inspection for damage is more critical for composite struc-

ture than for conventional structures. A large washer or
similar object is a valuable tool for detecting debonds in the
airframe surface. When a large washer is lightly bounced
against a solid structure, a clear metallic ring should be
heard. If delamination is present, a dull thud will be heard.
This procedure is shown in the following Figure 1:
Coin Tapping
Figure 1

PAGE 9
20-10-07 Flexible Hose
The EXTRA 300L is equipped for the oil, fuel, and brake
lines with "AEROQUIP-hoses Aerospace Division". From
Serial No. 35 equivalent "STRATOFLEX-hoses Aerospace
Connectors Division" are used. Later, from Serial No. 47
KNAPP hoses are used for the brake system in the cockpit
area and for the flight instruments. Alternatively PARKER/
STATOFLEX or AEROQUIP PTFE type hoses are used as
fuel, oil and sensing lines. Maintenance work or overhaul of
these hoses requires the attention of the manufacturer infor-
mations and bulletins. For the replacement of hose and hose
assemblies the EXTRA-Flugzeugproduktions- und Vertriebs-
GmbH should be contacted.
Replacement of Flexible Hose
Hose and hose assemblies should be checked for deteriora-

tion at each inspection period. Leakage, separation of the
cover or braid from the inner tube, cracks, hardening, lack of
flexibility, and excessive "cold flow" are apparent sign of
deterioration and reason for replacement. The term "cold
flow" describes the deep, permanent impressions in the hose
produced by pressure of hose clamps or supports.
The entire assembly must be replaced, if failure occurs in a
flexible hose before the time limit (refer to Chapter 05-10-
02 Overhaul Schedule) of the hose is achieved. Obtain a
new hose assembly of the correct size and length, complete
with factory-installed end fittings.
Installation of Flexible Hose Assemblies
The flexible hose must not be twisted on installation, since

this reduces the life of the hose considerably and may
loosen the fittings. Twisting of the hose can be determined
from the identification stripe running along its length.
The minimum bend radius for flexible hose varies according
to size and design of the hose and the pressure under which
the hose is to operate. Bends that are too sharp will reduce
the bursting pressure of flexible hose considerably below its
rated value.
PAGE DATE:
DATE:15.
1. December
PAGE 10
SERVICE MANUAL EXTRA 300L Flexible Hose
The flexible hose should be installed so that it will be subject

to a minimum of flexing during operation.
The AEROQUIP- hoses inside the engine compartment are
to be covered with AEROQUIP AE102 fire sleeves. The
correct size of fire sleeves can be taken from the following
table:
NOTE The STRATOFLEX-hoses used in the engine compart-

ment are factory equipped with fire sleeves.
Hose Fire sleeve
MIL-H-8794-4 / AE303-4 / 111-4 AE102-10
MIL-H-8794-6 / AE303-6 / 111-6 AE102-12
MIL-H-8794-8 / AE303-8 / 111-8 AE102-16
MIL-H-8794-10 / AE303-10 / 111-10 AE102-18
20-10-08 Fittings
Generally AN-fittings are used in the Extra 300L for the oil
lubrication, the fuel system, and the brake system (the latter
up to Ser. No. 46). All these fittings are made of aluminium
alloy and are colored blue for idendification purposes. The
dash number following the AN number indicates the size of
the hose for which the fitting is made, in 16ths of an inch.
This size measures the inner diameter (I.D.) of hose. The
material code letter (Aluminum alloy: code D) follows the
dash number.
Example: Elbow AN 822-8D
NOTE Apply Loctite 577 on all National Pipe Threads (NPT)

before installation.
PAGE DATE: 1.
15.June
December
1995 1999 CHAPTER 20
PAGE 11
EXTRA
20-20-00 ASSEMBLY INSTRUCTION
20-20-01 General
NOTE Make appropriate logbook entry of compliance with

this Assembly Instruction after Container Shipping.
In case of the aircraft is delivered in a container it has to be

assembled on arrival.
For assembly of aircraft main components follow the in-
structions as outlined in the Chapter 20-20-02.
These instructions can not replace the skill, craftsmanship
and sound technical knowledge of qualified personnel. In
case of doubt or lack of information, the manufacturer of the
respective component should be contacted for advice.
Unless otherwise specified all bolts and connections should
be torqued as listed in Chapter 20-10-03. At some locations
special torque values considered necessary. Refer to Chap-
ter 20-10-04. The stated direction "Front" and "Rear" are to
be considered in respect of pilot`s seating direction.
20-20-02 Assembly Instruction after Container

Shipping
Complete each step of the assembly procedure in the order

shown below.
1 Check the condition of fastening of the aircraft compo-
nents in the container. Note any damage.
2 Remove the fuselage/engine assembly from the con-
tainer. Prevent the aircraft from nosing over by keeping
down the tail.
3 Weight the tail per Chapter 07.
4 Remove the aircraft components out of the container.
Small parts, hardware, spinner dome and the wheel
fairings You find in the cockpit.

PAGE 12
EXTRA ASSEMBLY INSTRUCTION
SERVICE MANUAL EXTRA 300L Assembly Instruction after Container Shipping
5 Inspect all removed items for damage prior to assem-

bly. Damaged items have to be replaced or if possible
repaired according to Chapter 51.
CAUT I O N In order to prevent the aircraft from nosing over the

assembly has always to start with the empennage.
6 Prior to assembly remove engine cowlings, canopy, main

fuselage cover including the rear support angle per Chap-
ters 51 and 53.
NOTE In contrast to the instructions given in the respective

Chapters don‘t reinstall these items before completion
of the whole assembly.
7 Remove provisional attached rudder and vertical stabi-

lizer per Chapters 27 and 55.
8 Install horizontal stabilizer with elevator per Chapter 55.
The procedure described there is also applicable to the
installation of the complete horizontal tail. Consider to
connect the ground bonding lead of the elevator too.
9 Connect elevator push pull rod actuator lever per Chap-
ter 27-01-01.
10 Connect trim wire to the tab actuator lever using fitted
clamp.
11 Inspect for full travel and elevator deflection in relation
to stick movement.
12 Inspect for full travel and trim tab deflection in relation
to trim handle movement.
13 Install the vertical stabilizer per Chapter 55.
14 Reinstall rudder to the vertical stabilizer per Chapter
27-21-01.
15 Inspect for full travel and rudder deflection in relation
to rudder pedal movement.
16 Install the wing per Chapter 57.
17 Install navigation/strobe lights per Chapter 33-41-01.
18 Install propeller in accordance with MT-Propeller in-
stallation instructions E-124 latest revision.

PAGE 13
EXTRA ASSEMBLY INSTRUCTION
SERVICE MANUAL EXTRA 300L Assembly Instruction after Container Shipping
19 Remove tail weight.

20 Check if all switches are in Off-position and connect
battery.
21 Perform operational check of electrical equipment.
Shut-off master switch after completion.
22 Perform operational check and rigging of control sys-
tem.
23 Inspect fluid filled lines for leaks.
24 Check security of main spar bolts.
25 Install wheel fairings, main fuselage cover and rear sup-
port angle, canopy, engine cowlings, and access panels
(Refer to Chapter 51-00-01 and 53).
26 Check all control surfaces for freedom of movement
and security.
27 Perform a compass compensation according to „Aircraft
Inspection and Repair FAA AC 43.13“.
28 Check correct servicing of aircraft.
29 Perform an engine run up. Refer to Chapter "05-20-04
Scheduled Maintenance Checks". Start the engine in
accordance with the Pilot’s Operating Handbook and
Airplane Flight Manual (POH).
30 Inspect aircraft for foreign objects.
31 Final inspection by licensed aircraft inspector.
I M PO R TAN T After first flight check fuselage interior/exterior for

fuel leaks. Check all bolts on fairings and cover sheets
for tight fit.
PAGE DATE: 1. June

June 1995
1996 CHAPTER 20
PAGE 14
Chapter 23
Communication

PAGE 1
Table of Contents
Chapter Titl
23-00-00 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
23-10-00 SPEECH COMMUNICATION . . . . . . . . . . . . . . . . . 3

23-10-01 Becker AR 3201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
23-10-02 Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
23-10-03 VHF Whip antenna (Moba 210 FA) Becker 1A001 . . . . 5
23-40-00 INTERPHONE (INTERCOM) . . . . . . . . . . . . . . . . . . 7

PAGE 2
23-00-00 GENERAL
The aircraft is equipped with a BECKER communication

system. Maintenance work or overhaul of the this system
requires consultation of the manufacturer. (Refer to BECKER
Flugfunkwerk GmbH).
23-10-00 Speech communication
The VHF-communication system consists of:

1 transmitter/receiver, VHF radio BECKER AR 3201
2 circuit breaker 5Amp.
3 VHF whip antenna (Moba 210 FA) BECKER 1A001
4 switch (radio master)
5 Audio selector box
23-10-01 BECKER AR 3201
NOTE The informations given for VHF radio AR 3201 are

based on the manufacturer´s operator´s and installa-
tion manual. Refer to BECKER operator´s and instal-
lation manual for further information.
Operation Instructions
For a better understanding of the following operation in-

structions refer to Figure 1 additionally.
1 Switch on
2 Frequency selection
Frequency selection is only possible when the channel
selector knob is in the "A"-position.

PAGE 3
EXTRA - FLUGZEUGBAU GmbH SPEECH COMMUNICATION
SERVICE MANUAL EXTRA 300L BECKER AR 3201
3 Channel memories
The AR 3201 is fitted with 4 non-volatile channel memo-
ries, which can be programmed from the front panel.
4 Channel storage
- Turn the channel selector in position "A".
- Select the desired frequency with the double knob
- Switch the channel selector over to the desired channel
memory (1,2,3 or 4)
- Push the store key and hold it until the formerly stored
frequency disappears and the newly selected one ap-
pears on the LC-display.
5 Channel recall
Every stored frequency can be recalled by turning the
channel selector knob
6 Squelch
Bringing the ON\OFF switch into SQ position switches
the squelch on. This suppresses disturbing noises and
enhances the comfort of the radio communication.
volume control
M3-screw
store-key
LC-Display
ON/OFF switch
frequency
channel selection
selector knob double knob
Becker AR 3201 Front View

Figure 1

PAGE 4
SERVICE MANUAL EXTRA 300L BECKER AR 3201
Installation Instruction
The AR 3201 VHF transceiver is installed in the rear

instrument panel, rear mounted and secured with 4 M3-
screws. For the electrical installation the AR 3201 is inter-
connected through the wiring harness ref.431.001-950 fol-
lowing the wiring diagram (see section "Wiring Diagram" in
the Becker instruction booklet and refer to Chapter 92
"Schematics" in this manual).
23-10-02 Circuit Breaker
The AR 3201 VHF transceiver is protected against elect.

short circuit by a 5 Amp.circuit breaker on the rear instru-
ment panel.
23-10-03 VHF Whip antenna (Moba 210 FA)

BECKER 1A001
The VHF whip antenna is installed in the fuselage and is

towered with the whip into the rudder fin (Refer to Figure 2).
A "RG 50" coaxial cable connects this whip antenna directly
to the AR 3201 VHF transceiver.
whip antenna
Whip antenna
Figure 2

PAGE 5
SERVICE MANUAL EXTRA 300L VHF Whip antenna
The VHF whip antenna is removed as follows:

1 Assure the master switch is OFF
2 Remove the main fuselage cover and the tail fairing (Re-
fer to Chapter 05-00-01).
3 Disconnect the antenna to the coaxial cable.
4 Remove the nut holding the antenna to the grounding
plate
5 Pull the antenna carefully out of the rudder fin.

PAGE 6
23-40-00 INTERPHONE (INTERCOM)
The interphone (intercom) is useful in an aircraft with high

noise level where headseats are used. When the IC-switch
(located at the throttle lever) is pressed, the transceiver can
simultaneously operated for radio communication by the
PTT key. Additionally, the intercom between both crew
menbers is operational without any further action. This
mode is also known as "HOT MIKE", as the crew´s micro-
phones are permanently open. The intercom-connectors
(Figure 3) are mounted to the right side of the steel tube
frame next to the instrument panels.
Intercom-connectors
Figure 3

PAGE 7
EXTRA
Chapter 24
Electrical Power

PAGE 1
EXTRA
Table of Contents
Chapter Title
24-00-00 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
24-30-00 DC-GENERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
24-30-01 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
24-30-02 Master Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
24-30-03 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
24-30-04 Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
24-30-05 Alternator Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
24-60-00 DC ELECTRICAL LOAD DISTRIBUTION . . . . . . . 10

24-60-01 Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
24-60-02 Lever Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
24-60-03 Subminiature Pushbotton Switch . . . . . . . . . . . . . . . . . 11
PAGE DATE:
DATE: 4.
1.June
June2009
1995 CHAPTER 24
PAGE 2
EXTRA
24-00-00 GENERAL
This Chapter describes the electrical power system and its

operation. This covers the battery system and the alternator
system.
The battery system consists of the dryfit A200 battery
(Sonnenschein GmbH, Büdingen, Germany), the master relay
and the associated wiring. The battery is located in the
middle of the fuselage just behind the firewall; the master
relay at the left cockpit side of the firewall.
The alternator system consists of the alternator (PRESTO-
LITE; ALX8421LS) with integrated DC converter and the B-
00371-25 Lamar alternator control box which contains an
voltage regulator adjusted to 13.8 Volts and an overvoltage
trip cutting the circuit at 16 volts. The alternator is mounted
at the right front of the engine. The alternator control box is
located at the upper left of the firewall (cockpit side).

PAGE 3
EXTRA
24-30-00 DC-GENERATION
(Refer to Figure 0 of Chapter 91) Power for the electrical

system is provided by an alternator and/or the battery. The
alternator serves as the main component to power the
electrical system and charge the battery during normal
conditions. The battery is used for starting the engine and
powering the electrical system when alternator power is not
available (engine not running). The battery also powers the
electrical system in case of alternator failure.
A rocker type master switch is used for energizing the master
relay, which connects power to the electrical system. The
master switch is in series with the field switch so that the
complete electrical system can be cut of by means of a
master switch.
The voltage regulator, receiving power from the battery via
the master switch in combination with the field switch,
energizes the alternator field. With the alternator field ener-
gized, the operating alternator will produce an output to the
electrical system. The voltage regulator varies the output
voltage of the alternator to meet the requirements of the
electrical system loads. An ammeter is installed into the
system to provide an indication of current flow from or to
the battery.
The negative side of the battery is connected to the aircraft
steel tube design (negative ground). This provides a ground
for the system through use of the steel tube design. The
positive side of the battery is connected to the coil of the
master relay. This relay remains in relaxed state until the
master switch is placed to the ON-position. Placing the
master switch in the ON-position provides a ground for the
master relay energizing this relay. With the master relay
energized, a circuit exists from the battery through an
ammeter to the bus bar.
The bus bar powers the electrical equipment and accessories
furnished on the aircraft. The energized master relay will
also allow power from the battery to the starter relay.
Placing the field switch to the ON-position likewise will
provide a circuit from the bus bar through a 60 amp alternator
and a 5 amp alternator field circuit breaker to the voltage

PAGE 4
EXTRA DC-GENERATION
regulator. The voltage regulator will supply and regulate

voltage to the alternator field and protects circuit against
overvoltage. With the alternator operating (engine running)
and the field energized, the alternator will develop electrical
power. The alternator supplies power to the bus bar through
the 60 amp alternator circuit breaker. With the alternator
power available, the battery will be charged from the bus bar.
The ammeter, which is in series with the battery and the bus
bar will indicate the current flow to the battery. When the
battery reaches a state of full charge, the ammeter will show
an indication near "0".
I M PO R TAN T If replacement of wiring passing the firewall is neces-

sary, renew the sealing of the bushing grooves and gaps
at the engine side of the firewall. Use PRC-812 (Prod-
ucts Research & Chemical Corporation, USA) firewall
sealant.
24-30-01 Battery
Removal/Installation
CAUT I O N Ensure the master switch is in Off-position.
1 Remove the bottom fuselage cover and the LH cuff as

per Chapter 51-00-01.
2 Disconnect the electrical wiring.
3 Remove the 4 attachment nuts (LN9348-06) and the top
attachment frame.
4 Lift the battery out of its bottom frame and then remove
downwards.
5 Install in reverse sequence of removal.
PAGE DATE:
DATE: 4.
1.June
June2009
1995 CHAPTER 24
PAGE 5
EXTRA
24-30-02 Master Relay
CAUT I O N Ensure the master switch is in Off-position.
1 Remove the main fuselage cover as per Chapter 51.

2 Disconnect electrical wiring.
3 Remove the DIN933 M5x12 attachment bolts, the
DIN9021 M5x20 washers and the LN9348-05 stopnuts.
4 Remove the master relay.
24-30-03 Alternator
Instructions given below are only applicable for Bosch

alternators included in the type design. For the initially used
Electrosystems/Prestolite alternators refer to the
Maintenance Manual of the related Lycoming engine.
Figure 1,
Alternator and Accessories
PAGE DATE:
DATE: 4.
1.June
June2009
1995 CHAPTER 24
PAGE 6
EXTRA MAINTENANCE PRACTICES
Removal
1 Remove the upper and lower part of the cowling (ref.

Chapter 71).
2 Disconnect the wiring of the alternator.
3 Remove cotter pins at locknuts (2 & 3, Figure 1) and
safety wire at bolt (1).
4 Slightly loosen bolt (1) and locknut at bolt (2 & 3) to
release drive belt tension.
5 Rotate the alternator clockwise around bolt connection
(3).
6 Detach belt from the alternator pulley.
7 Remove locknuts (2 & 3) and pull bolts for removal of
the alternator from the attachment.
Installation
1 Install in reverse sequence of removal. Refer to Chapter

20-10-03 for torque values of bolt connections.
2 Apply a proper tension to the drive belt by counter-
clockwise rotating the alternator around bolt connection
(3, Figure 1).
3 Check tension of the drive belt and adjust if necessary
24-30-04 Drive Belt
Replacement
1 Remove cowling per Chapter 71.

2 Remove spinner per Chapter 51.
3 Remove Propeller according to MT Operation and
Installation Manual E-124 (see Chapter 1).
4 Remove cotter pins at locknuts (2 & 3, Figure 1) and
PAGE DATE:
DATE: 4.
1.June
June2009
1995 CHAPTER 24
PAGE 7
EXTRA
5 Slightly loosen bolt (1) and locknut at bolt (2 & 3) to

release drive belt tension.
6 Rotate the alternator clockwise around bolt connection (3).
7 Detach belt from the alternator pulley.
8 Remove starter ring gear according to applicable
Lycoming installation manual (see Chapter 1)
9 Remove belt.
10 Install in reverse sequence of removal. Refer to Chapter
20-10-03 for torque values of bolt connections.
11 Apply a proper tension to the drive belt by counter-
clockwise rotating the alternator around bolt connection
(3, Fig. 1).
12 Check tension of the drive belt and adjust for new drive
belt per next paragraphs.
13 Check drive belt tension after the first 1 to 1.5 hours of
operation and then after 8 hours of operation and adjust
for used drive belt per next paragraphs.
Tension Check
IMPORTANT An improperly tensioned alternator drive belt can slip,

wear prematurely, and reduce electrical output of the
alternator.
Use the following simple method (Torque Method) to check

proper tension of the drive belt. This method of checking
drive belt tension consists of measuring the torque required
to slip the drive belt at the small pulley and is accomplished
as follows:
1 Secure the propeller to prevent rotation of the engine.
2 Apply a torque indicating wrench to the nut that attaches
the pulley to the alternator and turn it in a clockwise
rotation. Observe the torque shown on the wrench at the
instant the pulley slips.
3 Check torque indicated in step 2 with the torque
specified in the following.
PAGE DATE:
DATE: 4.
1.June
June2009
1995 CHAPTER 24
PAGE 8
EXTRA
NOTE The higher drive belt tension specified in the following

for the new drive belt is to compensate for the initial
stretch that takes place as soon as it is operated. These
higher tension values should not be applied to drive
belts that have been used previously.
Condition: Torque indicated at alternator pulley

New drive belt: 15 to 18 Nm (10 to 13 ft.lbs.)
Used drive belt: 10 to 12 Nm (7 to 9 ft.lbs.)
4 Adjust belt tension accordingly.
Tension Adjustment
1 Remove cotter pins at locknut of bolts (2) & (3)

(Figure 1) and safety wire at bolt (1).
2 Slightly loosen bolt (1) and locknut of bolts (2) & (3).
3 Rotate the alternator counterclockwise around bolt
connection (3) to increase the belt tension. Rotate the
alternator clockwise around bolt connection (3) to
decrease the belt tension.
4 Fasten the locknut at bolts (2) & (3) and fasten bolt (1).
5 Install new cotter pins at locknut of bolts (2) & (3) and
24-30-05 Alternator Pulley
Removal
1 Remove the nut from the alternator drive shaft.

2 Remove the pulley from the alternator drive shaft (take
care of the feather key of the connection).
Installation

2 Apply proper torque value of 50 +/-5 Nm (37 +/-3 ft. lbs.).
3 Apply inspection lacquer.
PAGE DATE:
DATE: 4.
1.June
June2009
1995
1996 CHAPTER 24
PAGE 9
EXTRA
24-60-00 DC ELECTRICAL LOAD DISTRIBUTION
(Refer to Figure 0 of Chapter 91) From the main bus which

physically corresponds to the bus bar the electrical load is
distributed through circuit breakers and switches.The bus
bar is located at the back side of the circuit breakers, the
circuit breakers themselves are located at the rear instrument
panel so as the lever switches. Subminiature pushbotton
switches for the radio resp. intercom are mounted on the
control sticks and the throttle controls.
More information concerning the wiring shows Figure 0 of
Chapter 91.
I M PO R TAN T If replacement of wiring passing the firewall is neces-

sealant.
24-60-01 Circuit Breaker
1 Disconnect battery
2 Remove the instrument panel cover per Ch 31.
3 Disconnect the tubings from the resp. instruments.
4 Remove the instrument panel attachment screws.
5 Turn down the panel.
6 Loosen the bus bar attachment screws and remove bus
bar if necessary.
7 Disconnect wiring.
8 Remove the attachment nut at the front side of the in-
strument panel.
9 Remove the circuit breaker.
PAGE DATE:
DATE: 4.
1.June
June
June2009
1995
1996 CHAPTER 24
PAGE 10
EXTRA
24-60-02 Lever Switch
2 Remove the instrument panel cover per Ch 31.
3 Disconnect the tubings from the resp. instruments.
4 Remove the instrument panel attachment screws.
5 Turn down the panel.
6 Disconnect wiring.
7 Remove the attachment nut at the front side of the in-
strument panel.
8 Remove the combined switch and circuit breaker.
24-60-03 Subminiature Pushbotton Switch
2 Remove the attachment nut.
3 Tie out the switch some centimeters.
4 Loosen the soldered connections.
5 Remove the switch.
6 Install in reverse sequence of removal
PAGE DATE:
DATE: 4.
1.June
June2009
1995 CHAPTER 24
PAGE 11
Chapter 25
Equipment and Furnishings

PAGE 1
Table of Contents
Chapter Title
25-10-00 FLIGHT COMPARTMENTS . . . . . . . . . . . . . . . . . . . 3

25-10-01 Front Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
25-10-02 Rear Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
25-10-03 Seat Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
25-10-04 Aircraft Document Bag . . . . . . . . . . . . . . . . . . . . . . . . . 5
25-15-00 MAINTENANCE PRACTICES . . . . . . . . . . . . . . . . . . 6

25-15-01 Front Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
25-15-02 Rear Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

PAGE 2
25-10-00 FLIGHT COMPARTMENTS
The EXTRA 300L is standard equipped with a pilot and a co-

pilot seat including special aerobatic seat belt / shoulder
harnesses for both seats. An aircraft document bag is installed
in the rear cockpit.
25-10-01 Front Seat
The front seat is a nonadjustable one-piece composite de-

sign. It is connected to the fuselage by four screws at the top
of the backrest and by two screws at each seat-to-pedal
connection.
25-10-02 Rear Seat
The rear seat assembly consists of two parts. The seat and the
backrest are composite materials which are connected by
bolts to a separate steel frame resp. steel tubes which allow
adjustment. The front of the seat is connected to the fuselage
by bolts. The seat to backrest connection and the connections
to the fuselage are made by means of quickpins.
25-10-03 Seat Belts
(Refer to Figure 1) Each seat is equipped with a special

aerobatic seat belt / shoulder harnesses from the manufac-
turer "Hooker custom Harness". Such an assembly of straps
consists of a right and left shoulder harness, two right and
two left seat belts and a crotch strap.

PAGE 3
EXTRA - FLUGZEUGBAU GmbH FLIGHT COMPARTMENTS
SERVICE MANUAL EXTRA 300L Seat belts
Strap Assembly
Figure 1
Up to Ser. No. 45 each strap end is fitted with LN 9037-0820

bolts , LN9348-08 stop nuts and DIN 125 M8 washers to its
own fitting at the steel frame resp. at the underside of the
seat. From Ser. No. 46 the crotch strap ends are attached to
the seats by means of AN4 bolts, washers and nuts. The
shoulder strap loops of the front and rear seat are attached to
horizontal steel tubes as shown in Figure 2.
PAGE DATE: 15.

1. June
December
1995 1999 CHAPTER 25
PAGE 4
EXTRA - FLUGZEUGBAU GmbH FLIGHT COMPARTMENTS
SERVICE MANUAL EXTRA 300L Seat belts
Shoulder Strap Attachment

Figure 2
25-10-04 Aircraft Document Bag
The rear cockpit of the EXTRA 300L is furnished with an

aircraft document bag. This aircraft document bag is mounted
with three AN 526 C 1032 R8 bolts and DIN 9021 M5x20
washers on the right inside of the cockpit frame.

PAGE 5
25-15-00 MAINTENANCE PRACTICES
25-15-01 Front Seat
1 Remove canopy and main fuselage cover per Chapter

51-00-01.
2 Loosen the leather protection cuff from the control stick.
3 Remove front seat attachment screws.
4 Remove front seat.
5 Disconnect crotch strap from seat if necessary.
25-15-02 Rear Seat
1 Loosen the leather protection cuff from the control stick.

2 Remove quickpins of the backrest steel frame and the
backrest-to-seat connection.
3 Remove rear seat backrest.
4 Disconnect backrest from the steel tubes if necessary
by removing the resp. bolts.
5 Remove the seat attachment bolts (front side of the rear
seat) and the quickpins of the seat steel frame.
6 Remove the seat.
7 Disconnect seat from the steel frame and the crotch strap
if necessary ba removing the resp. bolts.
8 Assemble and install in reverse sequence of disassem-
bly resp. removal.

PAGE 6
EXTRA
Chapter 27
Flight Controls

PAGE 1
EXTRA Chapter 27
Table of Contents
Chapter Title
27-00-00 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
27-00-01 Free Play in the Control System . . . . . . . . . . . . . . . . . . 3
27-00-02 Control Rod Lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

27-01-01 Control Rod Removal/Installation . . . . . . . . . . . . . . . . . 7
27-01-02 Bellcrank Removal/Installation . . . . . . . . . . . . . . . . . . . 7
27-01-03 Front Control Stick Removal/Installation . . . . . . . . . . . 8
27-01-04 Rear Control Stick Removal/Installation . . . . . . . . . . . . 9
27-01-05 Torque Tube Removal/Installation . . . . . . . . . . . . . . . . 10
27-01-06 Control Rod Length Adjustment . . . . . . . . . . . . . . . . . 10
27-10-00 AILERONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
27-11-00 MAINTENANCE PRACTICES . . . . . . . . . . . . . . . . . 14

27-11-01 Aileron Removal/Installation . . . . . . . . . . . . . . . . . . . . 14
27-11-02 Aileron Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
27-11-03 Spade Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
27-20-00 RUDDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

27-21-01 Rudder Removal/Installation . . . . . . . . . . . . . . . . . . . . 19
27-21-02 Bottom Hinge Bracket Removal/Installation . . . . . . . . 19
27-21-03 Bottom Hinge Bellcranks Removal/Installation . . . . . . 19
27-21-04 Control Cable Removal . . . . . . . . . . . . . . . . . . . . . . . 19A
27-21-04 Control Cable Installation . . . . . . . . . . . . . . . . . . . . . 19A
27-21-05 Fairlead Removal/Installation . . . . . . . . . . . . . . . . . . . 21
27-21-06 Rudder Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
27-30-00 ELEVATOR AND TAB . . . . . . . . . . . . . . . . . . . . . . . . 23

27-31-01 Elevator Removal/Installation . . . . . . . . . . . . . . . . . . . 25
27-31-02 Trim Tab Removal/Installation . . . . . . . . . . . . . . . . . . . 25
27-31-03 Elevator Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
27-31-04 Trim Tab Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

1996 CHAPTER 27
PAGE 2
EXTRA
27-00-00 GENERAL
(Refer to Figure 1) The EXTRA 300L is standard equipped

with full dual primary flight controls including conventional
control sticks and adjustable rudder pedals. The control
surfaces are operated by a direct mechanical linkage. The
control surface deflections are shown in Figure 2. From Ser.
N° 19 there is a rubber plugged hole in the bottom fuselage
cover for rear torque tube bearing lubrication.
Controls
Figure 1
27-00-01 Free Play in the Control System
With controls (stick and rudder pedals) locked, the free play
measured at the control surfaces must not exceed the values
listed:
Aileron: ±1 mm*
* measured at the trailing edge
and max. chord Elevator: ±1 mm*
Trim tab: ±2 mm*
The rudder has a direct cable connection with retracting
springs and is therefore always under tension.
PAGE DATE: 1. June

June 1995
1996 CHAPTER 27
PAGE 3
EXTRA GENERAL
Control Surface Deflections

Figure 2
PAGE DATE: 16.

1. June
January
1995
2009 CHAPTER 27
PAGE 4
EXTRA GENERAL
27-00-02 Control Rod Lengths
The measurements given in this chapter refer to the dis-

tances between the centers of the rod end bearings (see
Figure 3).
Control Rod Measurement

Figure 3
Refer to the following Figure 4 for identification of the

control rods.
Control Rod Identification

Figure 4
Control rod Measurements

0 1020 mm
1 807 mm
2 645 mm
3 737 mm
4 762 mm
6 532 mm
7 1884 mm
8 420 mm

PAGE 5
EXTRA
NOTE When installing a bellcrank or control stick the spacer

sleeve inside the bearing could be displaced as shown
in Figure 5. Use a mandrel to adjust the spacer sleeve.
Spacer Sleeve Displaced

Figure 5
NOTE When installing a control surface use mandrels as

shown in the following Figure 6 to preset the control
surface. Then press out each mandrel by pushing a bolt
into the bearing.
Control Surface Mounting Aid

Figure 6

PAGE 6
27-01-01 Control Rod Removal/Installation
Refer to Figure 7. All control rods are attached to the control

levers in the same way with AN bolts, washers and self-
locking nuts. The control rods inside the wing are intercon-
nected by ground bonding leads fastened to the rod ends by
additional nuts. So the rod ends have to be disassembled,
when the ground bonding leads shall be disconnected. In this
case also refer to Chapter 27-01-06.
1 Remove the respective access panels.
NOTE In case of removal of the control rod connecting the

control sticks also observe the instructions given in the
Chapters 27-01-03 and -04.
2 Remove the M6 attachment bolts (1).

3 Remove the control rod.
4 Reverse procedure to install the control rod. Replace the
selflocking nuts.
27-01-02 Bellcrank Removal/Installation
Refer to Figure 7
2 Remove the adjacent control rods per Chapter 27-01-
01.
3 Remove the M5 attachment bolt (2).
4 Remove the bellcrank.
5 Reverse procedure to install the bellcrank using suffi-
cient washers (min. 2) at the nut side of the bolt to cover
the shank (except the rocker type bellcrank: use only one
washer on each side). Replace the selflocking nuts.
Observe the first Note of Chapter 27-01-00. To ensure
installation of the elevator rocker type bellcrank in cor-
rect direction this bellcrank is marked by an "F" which
indicates the front side (refer to Detail A of Figure 7).

PAGE 7
SERVICE MANUAL EXTRA 300L Bellcrank Removal/Installation
Control Levers and Rods Removal/Installation

Figure 7
27-01-03 Front Control Stick Removal/Installation
Refer to Figure 8.
1 Remove front seat per Chapter 25-15-01.
3 Remove the control stick attachment bolt (1).
4 Disconnect the control stick from the control rod per
Chapter 27-01-01. Use the control stick to move the con-
trol rod attachment bolt within the mounting hole area
(2).

PAGE 8
SERVICE MANUAL EXTRA 300L Front Control Stick Removal/Installation
Front Control Stick Removal/Installation

Figure 8
5 Remove the control stick.

6 Reverse procedure to install the control stick. Replace
the selflocking nuts. Observe the first Note of Chapter
27-01-00.
7 Check for potential chafing of the wiring after installa-
tion.
27-01-04 Rear Control Stick Removal/Installation
1 Remove rear seat per Chapter 25-15-02.

3 Bring the control stick in the foremost position and dis-
connect the control stick from the control rods per Chap-
ter 27-10-01.
4 Remove the control stick attachment bolt.
5 Remove the control stick.
6 Reverse procedure to install the control stick. Replace
the selflocking nuts. Observe the first Note of Chapter
27-01-00.
7 Check for potential chafing of the wiring after installa-
tion.

PAGE 9
27-01-05 Torque Tube Removal/Installation

2 Remove the control sticks and rods per Chapters 27-01-
01 and 27-01-03/04.
3 Loosen the bolts of the front and rear bearing blocks.
4 Disassemble the bearing blocks and remove the torque
tube.
5 Reverse procedure to install the torque tube. Ensure that
the lubrication hole of the rear bearing block is on the
bottom. Lubricate the rear bearing with Aeroshell grease
22C or equivalent (MIL-G-81322D).
27-01-06 Control Rod Length Adjustment
The standard measurements are given in Chapter 27-00-02

2 Disconnect one rod end from the respective bellcrank.
3 Loosen the check nut.
NOTE It might be necessary to adjust both rod ends to get the

correct length. In this case the free thread of both rod
ends should have the same length.
I M PO R TAN T Observe that the rod ends joined to the rocker type
bellcrank should be adjusted long enough not to ob-
struct the travel.
I M PO R TAN T Ensure that the threaded rod is visible in the check hole
(Figure 9) in any case.

PAGE 10
SERVICE MANUAL EXTRA 300L Control Rod Length Adjustment
Control Rod Check Hole

Figure 9
4 Turn the rod end in the desired direction to change the

length.
5 Ensure that the rod end is in proper alignment with the
respective control lever and tighten the check nut.
6 Reinstall the control rod per Chapter 27-01-01.
7 Ensure that the control rods don't jam when the control
sticks are moved between the extreme positions.

PAGE 11
EXTRA
27-10-00 AILERONS
(Refer to Figure 10) The aileron (1) is direct mechanical

linked to the control sticks (6, 7) by the aileron center
linkage (10) with spade arm, push-pull rods (8), bellcranks
(9) and the torque tube (5). The bell cranks have two sealed
ball bearings. Each aileron is mounted at three points in
spherical bearings pressed into aluminium hinge arms. For
lightning protection reason each hinge arm is grounded to
the corresponding attachment bracket at the aileron by bonding
leads. The rod end bearings of the push-pull rods located in
the wing are also interconnected by bonding leads. The travel
stops (22) are located at the torque tube next to the rear
control stick (7).
To reduce pilot's hand forces the hinge line of the ailerons is
positioned at 20 - 25% of the aileron chord. Furthermore,
the ailerons are equipped with spades. To prevent flutter the
ailerons are mass balanced in the overhanging leading edge.
Two access panels are located at the bottom surface of each
side of the wing.

PAGE 12
EXTRA

Figure 10
Aileron Control
Legend:
1 aileron
5 torque tube
6 front seat stick
7 rear seat stick
8 push-pull rods
PAGE
9 bellcranks
10 aileron center linkage
CHAPTER
22 travel stops
AILERONS
13
27
EXTRA
27-11-01 Aileron Removal/Installation
1 Disconnect the actuator rod from the aileron center link-

age.
2 Disassemble the spade if necessary observing the quan-
tity and location of washers.
3 Loosen the hinge bolts and the ground bonding leads
and remove the bolts.
4 Install in reverse sequence of removal. Ensure that the
spade is installed with the same quantity and location of
washers (refer to Figure 12). Observe the second Note
of Chapter 27-01-00.
27-11-02 Aileron Rigging
Before beginning any adjustments inspect control rods,

levers and hinges for signs of wear or damage, check if the
control rod lengths correspond with the measurements given
in Chapter 27-00-02. If necessary replace parts and correct
lengths per Chapter 27-01-06.
1 Secure the control stick in the neutral position.

2 Check if the control rods connecting the torque tube
and the inner wing bellcranks have a length of 532 mm
(Refer to Chapter 27-00-02).
3 Adjust length if necessary per Chapter 27-01-06.
4 Check if the ailerons are in 0°-position (The trailing edge
bottom of the aileron is in alignment with the trailing
edge bottom of the wing as shown in Figure 11).

PAGE 14
SERVICE MANUAL EXTRA 300L Aileron Rigging
Trailing Edge Alignment

Figure 11
5 If necessary adjust the length of the control rods con-

necting the aileron center linkage to the outer wing
bellcrank per Chapter 27-01-06.
6 Check if the left aileron travel is within the given toler-
ances (up/down 30° ±2°). Use a conventional protrac-
tor.
7 Adjust the travel stops if necessary.
8 Follow step 8 for the right aileron.
9 If the travel of the right aileron exceeds the given toler-
ances, contact the manufacturer.
10 Check if the movement of the control sticks is free over
the whole travel range and check if the rear control stick
travel is symmetrically to each side. If it is not contact
the manufacturer.
27-11-03 Spade Rigging
For roll trim the spade rigging angle of incidence has to be

changed. Insert washer(s) between the spade and the mount-
ing plate (refer to Figure 12). For example: When the
aircraft rolls to the left, insert washer(s) at the front attach-
ment bolt of the right spade.

PAGE 15
SERVICE MANUAL EXTRA 300L Spade Rigging
Spade Rigging
Figure 12

PAGE 16
EXTRA
27-20-00 RUDDER
(Refer to Figure 13) The rudder pedals (4) are connected via
a cable system (17) to the bottom hinge bellcrank (13). The
cables are guided by fairleads (11). Springs (20) keep the
cables under tension when they are not operated. Adjustment
of the rear pedals (18) is made via multihole rod. The rudder
(3) is mounted at three points in spherical bearings pressed
into a aluminium hinge resp. into aluminium hinge arms. For
lightning protection reason each hinge (arm) is grounded to
the corresponding attachment bracket at the rudder by bonding
leads. A travel stop plate is located at the bottom hinge
bracket. A second safety stop is located at the rudder pedal
bearing having the only purpose of protecting the lower
brake system fitting in case of rudder cable failure.
I M PO R TAN T This second stop must not be reached under normal

operation conditions. Missallignment or exessive elon-
gation of the rudder cabels will result in misuse of this
second stop and a subsequent overload of the rudder
bearing. An subsequent inflight failure of the footrest
could occur.
To prevent flutter the rudder is mass balanced. The mass

balance weight of the rudder is installed in the rudder horn.

1996 CHAPTER 27
PAGE 17
EXTRA

Figure 13
Rudder Control
3 rudder
4 rudder pedals
11 fairleads
13 bottom hinge bellcrank
17 rudder control cable
PAGE
18 sleeves
19 pulley
CHAPTER
20 cable fastening
18
27
RUDDER
EXTRA
I M PO R TAN T Perform checks 10-11 of "Flight Controls" presented

in Chapter 05-20-04 after each maintenance work af-
fecting the rudder control cables.
27-21-01 Rudder Removal/Installation

1 Disconnect the rudder control cables from the bottom
hinge bellcrank.
3 Install in reverse sequence of removal. Observe the sec-
ond Note of Chapter 27-01-00.
27-21-02 Bottom Hinge Bracket Removal/Installation
1 Remove the rudder per Chapter 27-21-01.

2 Loosen the attachment bolts.
3 Remove the bottom hinge bracket with the travel stop
plate.
27-21-03 Bottom Hinge Bellcranks Removal/

Installation

2 Loosen the attachment bolts.
3 Remove the bottom hinge bellcranks.
PAGE DATE:
PAGE DATE: 1.
1. June
June 1995
1996 CHAPTER 27
PAGE 19
27-21-04 Control Cable Removal
1 Remove the respective access panels

2 Remove the cable to fuselage attachment bolts.
3 Remove the cable to rudder bellcrank attachment bolts.
4 Cut the control cables behind the front shrinking sleeves
and behind the cable to cable connection.
5 Remove the control cable parts by pulling out to the back.
27-21-04 Control Cable Installation
Use only control cables manufactured by EXTRA

FLUGZEUGBAU GmbH. Those cables are prepared for
simply installation.
1 Remove the respective access panels per Chapter 51.

2 Secure the rudder (3, Figure 13) in 0°-position.
3 Mount the pre-assembled shackle of the longer control
cable to the LH cable fastening (20).
4 Slip 800 mm teflon protective hose on the control ca-
ble.
5 Thread the cable through the "S"-shaped tube at the pedal
and the pulley (19).
6 Adjust rear rudder pedals (4) in rearmost position.
7 Let the front end of the protective hose extend to 10 mm
in front of the pedal "S"-tube and cut the rear end 10 mm
in front of the pulley.
8 Slip 2 NICOPRESS (National Telephone Supply Co.,
Cleveland Ohio) 18-3-M sleeves (18) and a 771095
shrinking sleeve on the control cable.
9 Thread the free end of the control cable through the rear
fairleads (11) and the hole in the fabric to the tail.
PAGE DATE:
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June 1995
1996 CHAPTER
CHAPTER 27
PAGE
PAGE 19A
29
SERVICE MANUAL EXTRA 300L Control Cable Installation
10 Slip 600 mm teflon protective hose on the control cable

end. The protective hose should extend to the first
fairlead inside the fuselage.
11 Adjust rear pedals in middle position.
12 Fix rear pedals in vertical position (90° relative to the
footrest).
13 Pre-install the LN9355-06-20 bolt, the DIN 125 M6
washers (2 washers outside, 4 washers inside), the DIN
937 M6 castle nut, the DIN 94 cotter pin and the thim-
ble to the bottom hinge bellcrank.
14 Slip the 771095 shrinking sleeve and a NICOPRESS
18-3-M sleeve on the cable end.
15 Move the cable around the thimble and stretch the
control cable with a force that is equivalent to the trac-
tive effort of the rear pedal retracting spring.
I M PO R TAN T Clamping has to be performed in accordance with the

Service Bulletin 300-1-93 and the Instruction No. 32 of
the National Telephone Supply Co., Cleveland Ohio.
16 Consider to let a distance of 1 mm between the thimble

and the sleeve and clamp the sleeve.
17 Cut the free end of the cable 20 mm in front of the
sleeve.
18 Slip the shrinking sleeve on the cable end and heat up
with a heat gun.
19 Remove the pedal securing device.
20 Mount the pre-assembled shackle of the shorter con-
trol cable to the front pedal.
21 Thread the free end of the control cable through the
pulley, the front fairleads and the pre-installed NICO-
PRESS 18-3-M sleeves.
22 Fix the front pedal in vertical position (parallel to the
firewall).
23 Stretch the shorter control cable with a force that is
equivalent to the tractive effort of the front pedal re-
tracting spring.
PAGE DATE:
PAGE DATE: 1.
1. June
June 1995
1996 CHAPTER 27
PAGE 20
SERVICE MANUAL EXTRA 300L Control Cable Installation
I M PO R TAN T Clamping has to be performed in accordance with the

Service Bulletin 300-1-93 and the Instruction No. 32 of
the National Telephone Supply Co., Cleveland Ohio.
I M PO R TAN T To prevent twisting the cables clamp the sleeves in the

same plane.
24 Consider that the clamping area shall be 30 cm aft the

rear pulley and clamp the sleeves.
25 Cut the free end of the cable (20 mm behind the sleeve).
26 Slip the shrinking sleeve on the rear sleeve and heat up
with a heat gun (The front sleeve can be left free for
visual control of the cable-to-cable connection).
27 Remove the front pedal securing device.
28 Follow the steps 3 to 27 for the RH control cable.
29 Remove rudder securing devices.
30 Check free travel of rudder.
27-21-05 Fairlead Removal/Installation
1 Remove the fairlead retaining clip.

2 Pull the fairlead halves out of the sleeve.
3 Reverse procedure to install the fairlead.
27-21-06 Rudder Rigging
NOTE Inspect the control cables, the pulleys, the fairleads and
the bottom hinge assembly (with the travel stop plate)
for signs of wear or damage before beginning any ad-
justments. Replace parts if necessary.
1 Secure the rudder pedals in neutral position.

2 Check if the rudder is in 0°-position. (Rudder horn lead-
ing edge in alignment with the leading edge of the verti-
cal stabilizer.)
PAGE DATE:
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1. June
June 1995
1996 CHAPTER 27
PAGE 21
SERVICE MANUAL EXTRA 300L Rudder Rigging
3 Replace the control cables and adjust the length per

Chapter 27-21-04 if necessary.
4 Check if the rudder travel is within the given tolerances
(left/right 30° ±2°).
5 If the rudder travel is out of limits, contact the manu-
facturer for advice.
PAGE DATE:
PAGE DATE: 1.
1. June
June 1995
1996 CHAPTER 27
PAGE 22
EXTRA
27-30-00 ELEVATOR AND TAB
Refer to Figure 14. The two control sticks (6, 7) are con-
nected by a push-pull rod (8) inside the torque tube (5). The
control movements are transferred from the rear control
stick (7) to the elevator (2) by push-pull rods (8) and
bellcranks (9, 9a). The bellcranks have two sealed ball
bearings. The elevator is mounted at five points in spherical
bearings pressed into aluminium hinge arms. For lightning
protection reason each hinge arm is grounded to the corre-
sponding attachment bracket at the elevator by bonding
leads. The travel stops (22) are located at torque tube.
The mass balance weight (21) is mounted on the center
bracket of the elevator extending into the fuselage.
An access panel is located at the right side of the rear
fuselage.
Trim Tab
The elevator trim control lever (16) is located at the right

side in the rear cockpit. Pitch trim is done by means of the
trim tab (14) on the right elevator trailing edge operated by
a bowden cable mechanism (15). The trim tab is mounted by
two piano hinges.
The trim tab is not mass balanced.

PAGE 23
EXTRA
PAGE DATE:
DATE: 16.
1. June
January
1995
2009
Figure 14
Elevator and Trim Tab Control
2 elevator
5 torque tube
6 front seat stick
7 rear seat stick
8 push-pull rod
9 bellcrank
9a rocker type bellcrank
12 elevator actuator arm
14 trim tab
15 trim control bowden cable mechanism
PAGE
16 trim tab control lever
21 mass balance
CHAPTER
22 travel stops
ELEVATOR AND TAB
24
27
EXTRA
27-31-01 Elevator Removal/Installation

Before the removal of the elevator, the vertical stabilizer has
to be disassembled.
2 Remove the rudder per Chapter 27-21-01
3 Remove the vertical stabilizer per Chapter 55-21-01.
4 Loosen the bowden cables from the trim tab. If a re-
placement is necessary order new cable.
5 Disconnect the elevator actuator arm from the push-pull
rod.
7 Install in reverse sequence of removal. Observe the sec-
ond Note of Chapter 27-01-00.
27-31-02 Trim Tab Removal/Installation
1 Loosen bowden cables. If a replacement is necessary

order new cable.
2 Disconnect the safety cotter pins and remove the hinge
pins.
27-31-03 Elevator Rigging
I M PO R TAN T Before beginning any adjustments, inspect control rods,

levers and hinges for signs of wear or damage and check
if control rod lengths correspond with the measure-
ments given in Chapter 27-00-02. Replace parts and
correct lengths if necessary per Chapter 27-01-06.

PAGE 25
SERVICE MANUAL EXTRA 300L Elevator Rigging
1 Remove the canopy and the main fuselage cover per

Chapter 51 and the seats per Chapter 25.
2 Secure the rear control stick in the neutral position. (Ver-
tical back edge of the torque tube parallel to the control
stick like shown in Figure 15).
Neutral Position of the Rear Control Stick

Figure 15
3 Check if the elevator is in 0°-position. (Trailing edge

on chord line. Fasten a lath to the tip rib of the horizon-
tal tail per Figure 16 using adhesive tape.)
Lath on Chord Line

Figure 16

PAGE 26
SERVICE MANUAL EXTRA 300L Elevator Rigging
4 If necessary adjust the length of the middle tail control

rod per Chapter 27-01-06.
5 Check if the elevator travel is within the given toler-
ances (up/down 25° ±2°). Use a conventional protrac-
tor.
6 Adjust the travel stops if necessary.
7 Check if the rear control stick travel is symmetrically.
8 If it is not, contact the manufacturer.
27-31-04 Trim Tab Rigging
Refer to Figure 17.

1 Secure the rear control stick in normal position.
2 Secure the trim control lever (1) parallel to upper
longerons.
Trim Tab Rigging

Figure 17
3 Check fuselage bellcrank (3) is vertical to upper

longerons. If it is not, proceed as follows:
a Disconnect the rod end (4) from the fuselage bellcrank
(3) by removing the castle nut (5).
b Loosen the counternut from the rod end and screw the
rod end out or in as necessary to adjust the fuselage
bellcrank in vertical position. Ensure rod end is screwed
in for min. 10 rotations.
PAGE DATE: 16.

1. June
January
1995
2009 CHAPTER 27
PAGE 27
EXTRA
c Renew locking varnish.

d Reconnect the rod end.
e Repeat steps a thru d for the front rod end (2) if
necessary.
4 Bring the trim tab in 0°-position by replacing the
selflocking nuts (6 and/or 7).
5 Bring the trim lever in extreme positions and check if
trim tab travel is up -40° (tolerance ±5°) and down +50°
(tolerance ±5°). If it is not, check free travel of the trim
levers, fuselage bellcrank and bowden cables.
PAGE DATE: 16.

1. June
January
1995
2009 CHAPTER 27
PAGE 28
EXTRA
Chapter 28
Fuel
PAGE DATE:
DATE: 16.
1. June
January
1995
2009 CHAPTER 28
PAGE 1
EXTRA
TABLE OF CONTENTS
Chapter Title
28-00-00 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

28-01-01 Refueling/Defueling . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
28-01-02 Reduction of Fuel Tank Vapor Hazards . . . . . . . . . . . . . 7
28-10-00 STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

28-11-01 Center Tank Removal/Installation . . . . . . . . . . . . . . . . 12
28-11-02 Acro Tank Removal/Installation . . . . . . . . . . . . . . . . . . 12
28-11-03 Acro Tank Flop Tube Removal/Installation . . . . . . . . . 13
28-11-04 Wing Tank Inspection Door Removal/Installation . . . . 14
28-11-05 Wing Tank Outlets Removal/Installation . . . . . . . . . . . 15
28-11-06 Center Tank Filler Neck Removal/Installation . . . . . . . 16
28-11-07 Wing Tank Filler Neck Removal/Installation . . . . . . . . 16
28-11-08 Filler Neck Sealing Lip Replacement . . . . . . . . . . . . . 16
28-11-09 Ventilation Line Replacement . . . . . . . . . . . . . . . . . . . 17
28-20-00 DISTRIBUTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

28-21-01 Fuel Selector Valve and Control Rod
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 21
28-21-03 Gascolator Removal/Installation . . . . . . . . . . . . . . . . . 24
28-21-04 Electrical Boost Pump Removal/Installation . . . . . . . . 25
28-21-05 Fuel Line Replacement . . . . . . . . . . . . . . . . . . . . . . . . 26
28-40-00 INDICATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

28-41-01 Fuel Quantity Indicator Removal/Installation. . . . . . . . 30
28-41-02 Fuel Quantity Indicator Calibration (Center Tank) . . . . 31
28-41-03 Tubular Tank Unit (Center Tank)
28-41-04 Lever-type Tank Unit (Wing Tank)
28-41-05 Float Wire Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 33
PAGE DATE: 16.

1. June
January
1995
2009 CHAPTER 28
PAGE 2
EXTRA
28-00-00 GENERAL
The fuel system (refer to Figure 1) consists of one center

tank (3), an acro tank (8), two wing tanks (1), a fuel selector
valve (2), a gascolator (9) , an electrically driven auxiliary
pump (6) and an engine driven rotary pump (7). Concerning
the fuel drains (5) also refer to Chapter 12-10-03.
From serial number 1292 the EXTRA 300L is available ex
factory in two different fuel tank system configurations.
Configuration 1 is characterized by a center tank with 42 L
capacity as it is used for the former serial numbers.
Configuration 2 is characterized by a center tank with an
increased capacity of 60 L. This tank system is outlined on
the 2nd sheet of the respective figures.
On the rear instrument panel one fuel quantity indicator for
the center tank and one for the wing tanks (refer to Figure 12),
the switch for the boost pump and circuit breakers are
installed. The electrical wiring is shown on Figure 2.
For fuel tank capacities refer to Chapter 12-10-01.
PAGE DATE:
DATE: 16.
1. June
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1995
2009 CHAPTER 28
PAGE 3
EXTRA
PAGE DATE:
DATE: 16.
1. June
January
1995
2009
Figure 1, Sheet 1
Fuel System (Configuration 1)
Legend:
1 Wing tank
2 Selector valve
3 Center tank
4 3-port tee-block
5 Drain
6 Electric driven aux. pump
PAGE
7 Engine driven rotary pump
8 Acro tank
CHAPTER
9 Gascolator
4
28
GENERAL
EXTRA
PAGE DATE:
DATE: 16.
1. June
January
1995
2009
Figure 1, Sheet 2
Fuel System (Configuration 2)
Legend:
1 Wing tank
2 Selector valve
3 Center tank
4 3-port tee-block
5 Drain
PAGE
7 Engine driven rotary pump
8 Acro tank
CHAPTER
9 Gascolator
5
28
EXTRA GENERAL
Electrical Wiring
Figure 2
PAGE DATE: 16.

1. June
January
1995
2009 CHAPTER 28
PAGE 6
EXTRA
28-01-01 Refueling/Defueling
Refer to Chapter 12 for detailed refueling/defueling proce-

dures.
28-01-02 Reduction of Fuel Tank Vapor Hazards
General Precautions
During all ventilation or maintenance procedures involving

the fuel system, observe the following general precautions.
1 Defueling should be outdoors with the aircraft at least
100 feet from hangars or other aircraft.
2 No smoking should be allowed within 100 feet of the
aircraft.
3 Suitable fire fighting equipment should be available.
Foam or soda type extinguishing agents are recom-
mended.
4 Ground the aircraft to prevent static electricity from
causing sparks. If a ramp ground is available it should be
connected to exhaust stack. If a ramp ground is not
provided, a temporary ground can be obtained by driv-
ing a metal rod into the ground and attaching a ground
wire between the rod and the aircraft exhaust stack.
5 Flame and spark producing equipment should not be
operated within 100 feet of the aircraft.
6 The aircraft should have its battery removed.
7 Only personnel working on the aircraft should be allowed
in the immediate area, and no other maintenance should
be performed while the tanks are being worked on.
8 When a fuel tank is opened for repair, air ventilation
(refer to next paragraph) should be started immediately
to reduce vapor concentrations.
PAGE DATE: 16.

1. June
January
1995
2009 CHAPTER 28
PAGE 7
SERVICE MANUAL EXTRA 300L Reduction of Fuel Tank Vapor Hazards
9 When draining fuel, ensure that suitable containers are

available and that drained fuel is stored safely. Do not
allow fuel to drip to the ground and form pools.
10 If it is necessary to ventilate a tank when the aircraft is
in hangar, ensure that vapors do not accumulate to ex-
plosive or toxic levels in the hangar.
WAR N I N G When fuel is being drained, there is little control over

the release of fuel vapor. This vapor should be dissi-
pated as quickly as possible. Compressed air or explo-
sion-proof blowers may be used for the purpose.
Air Ventilation
1 Completely drain the fuel system per Chapter 12-10-

02.
2 Remove inspection doors (refer to Chapter 28-11-04)
and tank caps.
3 Use compressed air or an explosion-proof blower to
blow air into the tank until tank interior is dry and free
of vapor.
4 Continue ventilation whenever tank is open and being
worked on.
WAR N I N G If flammable vapors from cleaning solvents are allowed

in the tank increase air circulation to dissipate them.
PAGE DATE:
DATE:16.
1. January
June 1995
2009 CHAPTER 28
PAGE 8
EXTRA
28-10-00 STORAGE
The EXTRA 300L is equipped with two independent fuel

systems: The center- and acro tank system and the wing tank
system.
The acro tank (1, Figure 3) incorporating an inverted flight
fuel supply system is mounted in the fuselage just behind the
firewall. It is connected to the center tank (2) which is
mounted in front of the main spar area by a flexible hose.
Fueling the center and acro tank is by means of the fuselage
2" diameter filler cap (5). For leak detection the center and
the acro tank are furnished with a GRP tank shell. In case of
leakage blue colored fuel is shining through. The center and
the acro tank are grounded. The acro tank deaerates (a) into
the center tank that itsself deaerates by a ventilation tube (b)
ending at the right side of the main landing gear spring.
The root section of each wing – in front of the main spars –
forms an integral fuel tank of approximately 150 cm (59")
length (4). Each wing tank has a 2" diameter filler cap (5) for
gravity fueling. Sealing lips are installed at the filler necks
inside the wingtank. For sealing 3M Brand Fuel Resistant
Coating 776 (3M, St. Paul, USA) has been applied to the
inside of the wing tanks. For lightning protection reason the
shell in the area of the wing tank has an outer layer of carbon
fiber with incorporated aluminium thread (3). The wing tanks
are grounded. Each tank is provided with an alu ventilation
tube (c) for adequate venting. The ventilation tubes are
interconnected to a main tube (d), ending outside of the
fuselage at the right side of the main landing gear spring.
PAGE DATE: 16.

1. June
January
1995
2009 CHAPTER 28
PAGE 9
EXTRA STORAGE
Lightning strike protection layer
Ventilation lines
Center tank
Wing tank
Acro tank
Filler cap
Legend:
1
2
3
4
5
a-d
Storage (Configuration 1)
Figure 3, Sheet 1
PAGE DATE:
DATE: 16. January
1. June 2009
1995 CHAPTER 28
PAGE 10
EXTRA
Lightning strike protection layer
Ventilation lines
Center tank
Wing tank
Acro tank
Filler cap
Legend:
1
2
3
4
5
a-d
Storage (Configuration 2)
Figure 3, Sheet 2
PAGE DATE:
DATE:16.
1. June
January
1995
2009 CHAPTER 28
PAGE 11
EXTRA
28-11-01 Center Tank Removal/Installation
1 Remove the main fuselage cover (refer to Chapter 51).

2 Remove the front seat per Chapter 25.
3 Remove wing per Chapter 57 (60 L center tank only).
4 Remove the front control stick per Chapter 27.
5 Drain the fuel system per Chapter 12-10-02.
6 Loosen the electrical facilities and the hose fixtures.
7 Remove the bottom hose fitting of the center tank
(42 L center tank only, due to wing still installed).
8 Loosen and remove the metal attachment belts with the
rubber stripes.
9 Remove the center tank.
28-11-02 Acro Tank Removal/Installation
1 Remove the main fuselage cover and the 1. bottom

covering sheet per Chapter 51.
2 Remove the front seat per Chapter 25.
4 Loosen the electrical facilities and the hose fixtures.
5 Loosen and remove the metal attachment belts with the
rubber stripes.
6 Remove the acro tank.
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DATE: 16.
1. June
January
1995
2009 CHAPTER 28
PAGE 12
28-11-03 Acro Tank Flop Tube


2 Disconnect the hose (5, Figure 4) and the elbow fitting
(4).
3 Remove the acro tank per Chapter 28-11-02.
4 Loosen the flop tube fitting (3) and take the flop tube
assembly (2) out of the acro tank (1).
WAR N I N G Stripping solvents can be toxic and volatile. Use only

in well ventilated areas. Avoid physical contact with
solvent and do not inhale vapors. Keep solvent
containers covered when not in use.
5 Clean the sealing surfaces mechanically and with

Acetone.
NOTE If the flop tube assembly has to be replaced install a

complete new assembly (Part Number: PC-64204A21).
6 Install in reverse sequence of removal after applying

Loctite 577 to the flop tube fitting thread.
Flop Tube Removal/Installation

Figure 4
PAGE DATE:
DATE: 16.
1. June
January
1995
2009 CHAPTER 28
PAGE 13
28-11-04 Wing Tank Inspection Door


2 Disconnect the ground bonding leads and if necessary
(LH wing tank) the electrical wiring of the lever-type tank
unit (3, Figure 5).
3 Remove the inspection door bolts.
4 Remove the inspection door flange (1).
5 Push the inspection door (2) into the tank, then turn and
remove.

6 Clean the sealing surfaces mechanically and with Acetone.

7 Install in reverse sequence of removal after applying 3M
Brand Fuel Resistant Coating 776 (3M, St. Paul, USA)
to the sealing surfaces (inspection door and tank root rib).
Inspection Door Removal/Installation

Figure 5
DATE: 16.
PAGE 14
28-11-05 Wing Tank Outlets Removal/Installation
1 Remove the inspection door (1) (refer to Figure 6) per

Chapter 28-11-04.
2 Remove the union nuts (2) and the elbow tubes (3).
3 Remove AN 924 nut and washers and remove AN 832
fitting.

4 Clean sealing surfaces mechanically and with Acetone.

to the sealing surfaces (fitting to tank root rib). Ensure
that the outlet end positions are in the upper- resp. under-
most edge of the wing tank (see Figure 6 below).
Wing Tank Outlets Removal/Installation

Figure 6
PAGE DATE:
DATE:16.
1. January
June 1995
2009 CHAPTER 28
PAGE 15
28-11-06 Center Tank Filler Neck

1 Remove the main fuselage cover per Chapter 51.

2 Completely drain the fuel system per Chapter 12.
3 Loosen the lower hose clip.
4 Remove the filler neck.
28-11-07 Wing Tank Filler Neck Removal/Installation
1 Completely drain the fuel system per Chapter 12.

2 Remove wing tank inspection door per Chapter 28-11-
04.
3 Unscrew filler neck lock ring (4, Figure 7) with sealing
lip (5) using a tool as shown in Figure 7.
4 Remove filler neck (3) with filler cap (1) and O-ring
(2).

5 Clean all sealing surfaces with Acetone.

to the sealing surfaces (wing/filler neck).
28-11-08 Filler Neck Sealing Lip Replacement
1 Carefully drill out the body-bound rivets (7, Figure 7).

2 Install the new sealing lip driving in new washers (6)
and body-bound rivets.
PAGE DATE:
DATE: 16.
1. June
January
1995
2009 CHAPTER 28
PAGE 16
SERVICE MANUAL EXTRA 300L Filler Neck Sealing Lip Replacement
Filler Neck and Sealing Lip Removal/Installation

Figure 7
28-11-09 Ventilation Line Replacement
General information concerning fittings is found in Chapter

20-10-08.
PAGE DATE:
DATE:16.
1. January
June 1995
2009 CHAPTER 28
PAGE 17
EXTRA
28-20-00 DISTRIBUTION
(Refer to Figure 8) Flexible hoses and aluminium tubes

(A-K) connect the particular components of the fuel system.
From Serial No. 74 the drain line "L" has been added. The fuel
lines connecting the wing tanks (D) meet at an aluminium 3-
port tee-block (7) in the bottom center of the fuselage.
In addition to the engine driven fuel pump (6), an electrically
driven auxiliary pump (5) having sufficient capacity to feed
the engine at take-off power is fitted as a safety device
against failure of the engine driven pump. The auxiliary pump
switch is located on the rear instrument panel. A gascolator
(3) is installed between the fuel selector valve and the
auxiliary fuel pump at the firewall (engine side). A fuel
selector valve of an Allen 6S122 type (1) is located at the
right side of the front cockpit behind the main spar on a
separate support. A control rod connects the selector valve
to the control handles (2). The fuel selector valve is marked
by the letters "WT" (Wing Tank), "E" (Engine), and "CT"
(Center Tank) to ensure correct installation of fuel lines
(Refer to "Detail A" of Figure 9).
The two tank systems are equipped with separate drain lines.
Drains (4) are located at the gascolator and the left and right
side of the bottom fuselage.
PAGE DATE:
DATE:16.
1. January
June 1995
2009 CHAPTER 28
PAGE 18
EXTRA
PAGE DATE:
DATE: 16.
1. June
January
1995
2009
Figure 8, Sheet 1
Distribution (Configuration 1)
Legend:
1 Fuel selector valve
2 Control rod and handles
3 Gascolator
4 Drain
PAGE
6 engine driven rotary pump
CHAPTER
7 3-port tee-block
A-L Fuel lines
19
28
DISTRIBUTION
EXTRA
PAGE DATE: 16.

1. June
January
1995
2009
Figure 8, Sheet 2
Distribution (Configuration 2)
Legend:
1 Fuel selector valve
2 Control rod and handles
3 Gascolator
4 Drain
PAGE
6 engine driven rotary pump
CHAPTER
7 3-port tee-block
A-L Fuel lines
20
28
EXTRA
28-21-01 Fuel Selector Valve and Control Rod

(Refer to Figure 9 Sheet 1 resp. Sheet 2 from Serial No. 79)

2 Disconnect the fuel lines on the selector valve.
3 Remove the control rod attachment bolts (5).
4 Remove the attachment screw (4) if applicable.
5 Remove the control handle (3, Sheet 1) resp. the control
bracket (3, Sheet 2).
6 Remove the selector valve attachment bolts (2).
7 Remove the selector valve (1).
8 Remove the rear control rod connection bolt (11).
9 Pull out the control rod (12) to the rear.
10 Remove the front control rod connection bolt (7).
11 Remove the washers (8) and the spring (9), the front (6)
and the middle control rod (10).
I M O R TAN T Ensure LOCTITE 243 cannot get into the selector valve.
The selector valve could lock.
12 Install in reverse sequence of removal. Use LOCTITE

243 when installing the selector valve attachment bolts
(2) and the attachment screw (4).
PAGE DATE: 16.

1. June 1995
PAGE 21
EXTRA
PAGE DATE:
DATE: 16.
1. June
January
1995
2009
Legend:
Figure 9, Sheet 1
1 Selector valve
2 Selector valve attachment bolts
3 Control handle
4 Attachment screw
Fuel Selector Valve and Control Rod (up to SN 78)

5 Control rod attachment bolts
6 Front Control rod
7 Front control rod connection bolt
8 Washers
9 Spring
PAGE
10 Middle control rod with handle
11 Rear control rod connection bolt
CHAPTER
12 Rear control rod with handle
22
28
MAINTENANCE PRACTICES
EXTRA
PAGE DATE:
DATE: 16.
1. June
January
1995
2009
Legend:
Figure 9, Sheet 2
1 Selector valve
2 Selector valve attachment bolts
3 Control bracket
4 Attachment screw
Fuel Selector Valve and Control Rod (from SN 79)

5 Control rod attachment bolts
6 Front Control rod
7 Front control rod connection bolt
8 Washers
9 Spring
PAGE
10 Middle control rod with handle
11 Rear control rod connection bolt
CHAPTER
12 Rear control rod with handle
23
28
28-21-03 Gascolator Removal/Installation

2 Disconnect the fuel lines on the gascolator.
3 Loosen the knurled nut (1, Figure 10).
4 Remove the mounting bracket (2).
5 Remove the fuel reservoir (3) and the sealing ring (4).
6 Remove the strainer (5) and the gascolator cover (6).
Gascolator Removal/Installation
Figure 10
PAGE DATE: 16.

1. June
January
1995
2009 CHAPTER 28
PAGE 24
28-21-04 Electrical Boost Pump Removal/Installation

2 Disconnect the plug and the fuel lines on the boost pump.
3 Loosen the screw clamps (1, Figure 11).
4 Remove the boost pump (2).
Boost Pump Removal/Installation

Figure 11
PAGE DATE: 16.

1. June 1995
PAGE 25
28-21-05 Fuel Line Replacement
General information concerning hoses and fittings you find

in Chapter 20-10-07/08.
I M PO RTANT If replacement of fuel lines passing the firewall is nec-

essary, renew the sealing of the rubber grommet
grooves and gaps at the engine side of the firewall. Use
PRC-812 (Products Research & Chemical Cor-
poration, USA) firewall sealant. Cover the fuel lines of
the engine department with AEROQUIP AE102 fire
sleeves as per Chapter 20-10-07.
PAGE DATE:
DATE:16.
1. January
June 1995
2009 CHAPTER 28
PAGE 26
EXTRA
28-40-00 INDICATING
(Refer to Figure 12) For fuel contents indicating the center

tank is equipped with a tubular tank unit (1) and the left wing
tank with a lever-type tank unit (2). They transmit the fuel
levels to the respective fuel quantity indicators at the
instrument panel (3). In contrast to the fuel quantity indica-
tor of the center tank the one in the wing tank is not
adjustable. If the indication is inexact the float wire of the
tank unit has to be adjusted (refer to Chapter 28-41-05).
PAGE DATE: 16.

1. June
January
1995
2009 CHAPTER 28
PAGE 27
EXTRA INDICATING
fuel quantity indicators

lever-type tank unit
tubular tank unit
Legend:
1
2
3
Indicating (Configuration 1)
Figure 12, Sheet 1
PAGE DATE: 16. January

1. June 2009
1995 CHAPTER 28
PAGE 28
EXTRA
fuel quantity indicators

lever-type tank unit
tubular tank unit
Legend:
1
2
3
Indicating (Configuration 2)
Figure 12, Sheet 2
PAGE DATE:
DATE:16.
1. January 2009
PAGE 29
EXTRA
28-41-01 Fuel Quantity Indicator

1 Disconnect battery.
2 Loosen the nuts, remove

the mounting bracket
and remove the fuel
quantity indicator.
3 Disconnect the wiring

(the lamp is not used).
4 Install in reverse se-

quence of removal ob-
serving the wiring dia-
gram.
PAGE DATE: 16. January

1. June 2009
1995 CHAPTER 28
PAGE 30
28-41-02 Fuel Quantity Indicator Calibration

(Center Tank)
1 Drain the fuel system (refer to Chapter 12-10-02).

2 Remove the fuel quantity indicator following step 2 of
Chapter 28-41-01.
3 Bring indicator to „0“-
position by turning the
adjustment screw.
4 Reinstall the fuel quantity indicator.
28-41-03 Tubular Tank Unit (Center Tank)


2 Loosen one bolt and re-
place by a M5 threaded
rod (1) for securing the
slotted retainer ring (2).
3 Remove the other bolts
and the ground bonding
lead (3).
4 Lift tubular tank unit and sealing ring over the threaded
rod.
5 Remove the threaded rod
and turn out the slotted re-
tainer ring (2).

PAGE DATE:
DATE:16.
1. January
June 1995
2009 CHAPTER 28
PAGE 31

for sealing to both sides of the sealing ring.
28-41-04 Lever-type Tank Unit (Wing Tank)

(refer to Figure 13 below)

2 Remove LH inspection door (refer to Chapter 28-11-03)
3 Remove tank unit bolts (1).
4 Remove the retainer ring (3) the tank unit (4) and the
sealing ring (2).
Lever-type Tank Unit (Wing Tank) Removal/Installation

Figure 13

PAGE DATE:
DATE:16.
1. January
June 1995
2009 CHAPTER 28
PAGE 32

for sealing to both sides of the sealing ring and the grooves
inside the tank.
28-41-05 Float Wire Adjustment
1 Remove the lever-type tank unit per Chapter 28-41-04.

2 Remove the float wire and bend it in form like shown in
the following Figure 14:
Float Wire Adjustment

Figure 14
3 Reinstall the float wire observing the dimensions shown

in Figure 15, pay attention to a proper alignment and
tighten well the attachment bolt.
PAGE DATE: 16.

1. June
January
1995
2009 CHAPTER 28
PAGE 33
EXTRA
Float Wire Installation

Figure 15
4 Reinstall the lever-type tank unit per Chapter 28-41-04.
PAGE DATE: 16.

1. June
January
1995
2009 CHAPTER 28
PAGE 34
EXTRA
Chapter 31
Indication \ Recording System

PAGE 1
EXTRA
TABLE OF CONTENTS
Chapter Title
31-00-00 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
31-10-00 INSTRUMENT AND CONTROL PANELS . . . . . . . . 4

31-10-01 Rear Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . 4
31-10-02 Front Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . 6
31-10-03 Rear Instrument Cover . . . . . . . . . . . . . . . . . . . . . . . . . . 8
31-10-04 Typical Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
31-50-00 CENTRAL WARNING SYSTEMS . . . . . . . . . . . . . . 10

31-50-01 Stall Warning System. . . . . . . . . . . . . . . . . . . . . . . . . . 10
PAGE DATE:
PAGE DATE:1.
4.June
June1995
2009 CHAPTER 31
PAGE 2
EXTRA
31-00-00 GENERAL
The Extra 300L is equipped with flight instruments in both

cockpits. Instruments and placards can be provided with
markings in either metric or English units (refer to
Chapter11"Placards and Markings"). The colour markings in
instruments follow US-FAR, part 23 recommendation.

PAGE 3
EXTRA
31-10-00 INSTRUMENT AND CONTROL PANELS
31-10-01 Rear Instrument Panel
The instrument panel of the rear cockpit consist of a top

panel sheet (instrument panel) with an instrument cover and
a center panel sheet (control switch and circuit breaker
panel). The panels and the cover are mounted on the steel
frame with AN 526 C 1032 R8 bolts.
For panel arrangement of the rear cockpit refer to Figure 1
and the adjacent chart.
NOTE The chart may be modified by the minimum equipment

requirements of individual certifiying authorities.

1997 CHAPTER 31
PAGE 4
EXTRA INSTRUMENT AND CONTROL PANELS
SERVICE MANUAL EXTRA 300L Rear Instrument Panel
Rear Instrument Panel

Figure1
Pos. Item
1 Magneto Selector Switch & Starter
2 Amperemeter
3 Airspeed Indicator
4 Magn. Direction Indicator
5 Oil Pressure / Oil Temperature
6 EGT / CHT
7 COM
8 RPM Indicator
9 Circuit Breaker
10 g-meter
11 Manifold Pressure / Fuel Flow
12 Altimeter
13 Master switch
14 Fuel Quantity Acro Tank
15 Fuel Quantity Wing Tank

PAGE 5
EXTRA INSTRUMENT AND CONTROL PANELS
31-10-02 Front Instrument Panel
Up to Serial No. 26 an altimeter and an airspeed indicator are

mounted in the main fuselage cover in front of the front pilot
seat.
From Serial No. 27 these instruments (2, 3, Figure 2) are
installed on a separate removable instrument panel (1) in-
corporating shock mounts.
Front Instrument Panel

Figure 2
Removal/Installation (from Serial No. 27)
CAUT I O N Hold instruments and panel by hand to prevent from

falling down when removing the instrument panel at-
tachment screws.
1 Remove the AN526 C-1032-R6 instrument panel attach-

ment screws (3, Figure 3).
2 Disconnect the pitot resp. static lines from the instru-
ments (7). Mark lines for later identification.
3 Remove instrument panel (5) and frame (6).
4 Remove DIN 912 M4x20 screws (4) if removal of in-
struments is necessary.
5 Remove DIN 912 M4x5 bolts (2) and shock mounts (1)
with LN 9348 M4 stop nuts for disassembly of instru-
ment panel and frame.
6 Reverse procedure for assembly/installation.
PAGE DATE:
PAGE DATE:1.
4.June
June1995
2009 CHAPTER 31
PAGE 6
EXTRA
Front Instrument Panel Removal/Installation

Figure 3
PAGE DATE:
PAGE DATE:1.
4.June
June1995
2009 CHAPTER 31
PAGE 7
EXTRA
31-10-03 Rear Instrument Cover
1 Remove the screws located at the top of the front seat

back rest (1, Figure 4).
2 Remove the outer screws (2) of the rear instrument panel
(the two inner screws connect the panel to the steelframe).
3 Remove the cockpit corner cover screws (3).
4 Remove the instrument and the cockpit corner covers.
Instrument Cover Removal/Installation

Figure 4
PAGE DATE:
PAGE DATE:1.
4.June
June1995
2009 CHAPTER 31
PAGE 8
31-10-04 Typical Instruments
In Figure 5 typical instrument attachments used in the EXTRA

300L are outlined.
1 Switch off aircraft power
2 Remove main fuselage cover per Chapter 53.
3 Remove rear instrument panel cover if applicable per
Chapter 31-10-03.
4 Disconnect cable and/or sense line from the instrument.
5 Remove screws, nuts or clipnuts as applicable.
6 Remove gauge from panel.
Figure 5
Typical Instrument Attachments
PAGE DATE:
PAGE DATE:1.
4.June
June1995
2009 CHAPTER 31
PAGE 9
SERVICE MANUAL EXTRA 300L Front Instrument Panel
31-50-00 CENTRAL WARNING SYSTEMS
31-50-01 Stall Warning System
The EXTRA 300L is equipped with a stall warning system as

standard. This system is designed to warn the pilot by an
audible alarm horn, which is fitted in the back of the front
seat. The stall warning switch is located at the RH wing
leading edge. The electrical circuit of the stall warner is
independently secured with an automatic 1 ampere circuit
breaker in the rear instrument panel.
The stall warning switch has been adjusted at the factory after
a test flight. It is set to trigger the warning approx. 5-10 knots
prior to stalling in normal flight. The switch should require
no adjustment in normal service.

PAGE 10
Chapter 32
Landing gear

PAGE 1
Table of Contents
Chapter Title
32-10-00 LANDING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

32-11-01 Main Landing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
32-11-02 Top Half of the Mounting Clamp . . . . . . . . . . . . . . . . . . 4
32-11-03 Tail spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
32-11-04 Tail Wheel Fork Assembly . . . . . . . . . . . . . . . . . . . . . . . 6
32-11-05 Tail Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
32-40-00 WHEELS AND BRAKES . . . . . . . . . . . . . . . . . . . . . . . 8

32-40-01 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
32-41-00 MAINTENANCE PRACTICIES . . . . . . . . . . . . . . . . 13

32-41-01 Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1. June
1996 CHAPTER 32
PAGE 2
32-10-00 LANDING GEAR
The EXTRA 300L is designed as a conventional tail wheel

airplane, with an unretractable landing gear.
The landing gear consists of a 2 wheel main landing gear and
a tail wheel.
The main wheels are interconnected and attached to the
fuselage by means of an U-shaped carrier. This carrier is of
integral glasfibre design and incorporates wheel alignement,
spring and dampening action.
The tail wheel is self steering with full swivel capability.
The values for wheel rake and toe-in of main landing gear are
given in Figure 1A.
Wheel Rake
10° 10°
Tolerance ± 0.5°
Toe-in
1.5°
Flight Direction
1.5°
Tolerance ± 0.5°
Values are given for landing gear unloaded
Wheel Rake and Toe-in

Figure 1A

1996 CHAPTER 32
PAGE 3
32-11-01 Main Landing Gear
Refer to Figure 1
1 Remove the engine cowling, the landing gear cuffs and
the bottom covering sheet as per chapter 51-00-01.
2 Shore the aircraft as per Chapter 07-20-00
3 Drain brake system.
4 Unfasten the ventilation tubings and brake lines, and dis-
connect the brake lines from the brake assembly.
5 Remove the four landing gear attachment stop nuts
(LN9348-10) (1) and the DIN 125 M10 washers.
6 Remove the bottom halves of the mounting clamps (2),
the anti abrasion strips (3) and the landing gear (4).
7 Install in reverse sequence of removal using new stop
nuts. For correct position of landing gear the mandrel,
which is located at the bottom of the fuselage, is to put
into the respective sleeve at the top of the landing gear
spring. Replenish brake fluid.
32-11-02 Top Half of the Mounting Clamp
Refer to Figure 1
1 Remove the main landing gear as per Chapter 32-11-01.
2 Remove the LN9348-10 stop nuts, the DIN125 M10
washers and the LN9037-10054 bolts (5).
3 Remove the top half of the mounting clamp (6).
4 Reverse procedure for installation.

1996 CHAPTER 32
PAGE 4
EXTRA - FLUGZEUGBAU GmbH MAINTENANCE PRACTICES
SERVICE MANUAL EXTRA 300L Top Half of the Mounting Clamp
Main Landing Gear Mounting

Figure 1
32-11-03 Tail spring
Refer to Figure 2.
1 Shore the tail as per Chapter 07-20-02.
2 Remove the tail cone access panel as per Chapter 51-
00-01.
3 Remove the tail spring attachment bolts (1-3).
4 Remove the tail spring (4).
5 Reverse procedure for installation; consider to fasten
the breather line using the MS21919-DG12 clamp (5).

PAGE 5
32-11-04 Tail Wheel Fork Assembly
Disassembly/Assembly
Refer to Figure 2.
2 Remove the attachment bolt, washers and stopnut (6).
3 Disassemble the special washers (7), bearings (8), and
the tail wheel fork (9).
4 Reverse procedure for assembly.
32-11-05 Tail Wheel
Disassembly/Assembly
Refer to Figure 2.
2 Remove the attachment bolt, washers, and stopnut (10).
3 Remove the tailwheel.
4 Disassemble the bearings (11), the wheel halves (12),
the spacer sleeve (13), and the solid ruber tire (14).
5 Reverse procedure for assembly.
.

PAGE 6
Note:
From Serial N° 21 the tail
spring consist of a compos-
ite part and a steel shoe
connected by two bolts.
Tail Wheel, Fork and Spring

Figure 2
1. June
1996 CHAPTER 32
PAGE 7
32-40-00 WHEELS AND BRAKES
32-40-01 General
This Chapter provides maintenance personnel with neces-

sary procedures to accomplish both on-aircraft and off-
aircraft maintenance of Cleveland design wheel and brake
assemblies. Such maintenance shall include inspection,
removal, servicing, refinishing, and installation of assem-
blies.
The main wheels have standard brand 500x5 rims, six-ply
rated 5.00-5-tyres with tubes, according to FAA Standard
TSO-C62. Cleveland 40-151 wheels with 30-164 brake
assemblies are used. The main wheels are covered with glas
fibre designed fairings of which Figure 3 shows the layer
sequence.
The tailwheel consists of a 5 inch tire and an aluminium rim.
The Cleveland design features an external brake in which the
disc is external to the wheel with the brake caliper floating
over the disc.
The brake system (refer to figure 4) consists of a brake
assembly located at the inner side of the wheel, a master
cylinder (1) at the front and rear rudder pedals each, and a
brake fluid reservoir (2) mounted at the engine side of the
firewall. The master cylinders are mounted in line, so that the
front cylinder looses his efficasy, when the rear cylinder has
been actuated. The particular parts of the brake system are
interconnected by brake lines consisting of aluminium tubes
and flexible hoses (In Figure 4 details are only outlined, for
accurate identification of parts refer to Fig. 5. The capital
letters in Fig. 5 refer to the marks in Fig. 4). However from
Serial No. 47 the brake lines in the cockpit area are replaced
by a KNAPP hose system.
The tail wheel has no brake.
I M PO R TAN T Test brakes after maintaining the brake system. Actu-

ated brakes shall keep the aircraft standing with engine
runnung at 1.800 rpm and maximum propeller angle of
attack. With applied brakes and powersetting above
1800 rpm the wheels may slide on grass.
PAGE DATE: 1.
15.June 1995
December
June 1996 1999 CHAPTER 32
PAGE 8
EXTRA - FLUGZEUGBAU GmbH WHEELS AND BRAKES
SERVICE MANUAL EXTRA 300L General
NOTE For further information concerning main wheels and

brakes refer to Cleveland Wheels and Brakes Mainte-
nance Manual.
Layer Sequence Wheel Fairing, up to Ser. No. 49

Figure 3, Sheet 1
PAGE DATE: 1.
15.June 1995
December
June 1996 1999 CHAPTER 32
PAGE 9
Layer Sequence Wheel Fairing from Ser. No. 50

Figure 3, Sheet 2
PAGE DATE: 1.
15.June 1995 1999
December CHAPTER
CHAPTER 32
PAGE
PAGE 14
9A
Brake System
Figure 4

PAGE 10
Brake assembly to rear fitting shackle connection (A) Fittings and washers
1 AEROQUIP 816-4D
PN: PC-00901
2 AN816-4D
PN: PC-00159
3 AN818-4D
PN: PC-00161
4 AN819-4D
PN: PC-00860
5 AN822-4D
PN: PC-00155
6 AN823-4D
PN: PC-00167
7 AN832-4D
PN: PC-00171
Rear fitting shackle to rear pedal bottom port connection (B) 8 AN833-4D
PN: PC-00173
9 AN834-4D
PN: PC-01644
1 0 AN837-4D
PN: PC-00174
1 1 AN924-4D
PN: PC-00178
1 2 AN960-C716
PN: PC-00810
Hoses
Rear pedal top port to rear fitting shackle connection (C) 2 0 AEROQUIP 701-4
PN: PC-00910
Tubes
30 alu tube 5052-0, Ø1/4 inch
PN: PC-00123
Rear fitting shackle to front fitting shackle connection (D)
Brake Lines
Figure 5, Sheet 1

PAGE 11
Front fitting shackle to front pedal bottom port connection (E) Fittings and washers
1 AEROQUIP 816-4D
PN: PC-00901
2 AN816-4D
PN: PC-00159
3 AN818-4D
PN: PC-00161
4 AN819-4D
PN: PC-00860
5 AN822-4D
PN: PC-00155
6 AN823-4D
PN: PC-00167
Front pedal top port to center fitting shackle connection (F) 7 AN832-4D
PN: PC-00171
8 AN833-4D
PN: PC-00173
9 AN834-4D
PN: PC-01644
1 0 AN837-4D
PN: PC-00174
1 1 AN924-4D
PN: PC-00178
1 2 AN960-C716
PN: PC-00810
Hoses
2 0 AEROQUIP 701-4
Center fitting shackle to firewall connection (G) PN: PC-00910
Tubes
30 alu tube 5052-0, Ø1/4 inch
PN: PC-00123
Firewall to single brake fluid reservoir connection (H)
Brake Lines
Figure 5, Sheet 2

PAGE 12
32-41-00 MAINTENANCE PRACTICIES
32-41-01 Master Cylinder
1 Drain the brake system.

2 Disconnect the fuel lines.
3 Fix the master cylinder spring using a mounting aid as
shown in Figure 6 (Cleveland master cylinder only).
4 Remove the attachment bolts.
5 Remove the master cylinder.
7 Remove mounting aid (Cleveland only).
Master Cylinder Mounting Aid

Figure 6
PAGE DATE: 15.

1. June
December
1995 1999 CHAPTER 32
PAGE 13
Chapter 33
Lights

PAGE 1
Table of Contents
Chapter Title
33-10-00 FLIGHT COMPARTMENT . . . . . . . . . . . . . . . . . . . . 3
33-40-00 EXTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

33-41-01 Navigation/Strobe Lights
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
33-41-02 Strobe Light Power Supply
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

PAGE 2
33-10-00 FLIGHT COMPARTMENT
For controlling the generator function a low voltage monitor

is installed at the rear lower instrument panel. The indicator
is dimmable and has a built-in bulb testing device („press to
test“).
The electrical wiring is panel internal.

PAGE 3
33-40-00 EXTERIOR
Refer to Figure 1. The lighting units (1) installed at the wing

tips incorporate the red or green navigation lights on the
forward section, a strobe light in the center and a clear tail
position light on the aft section. They are mounted at the
wing tip panel (2). The strobe light power supplies (10) are
mounted on special attachment plates (11) inside the wing.
The wiring is routed through an aluminium tube inside the
wing and along the left resp. right upper longeron to the rear
instrument panel. Ground bonding leads are installed be-
tween the fuselage, the aluminium tube, (the pitot tube
* LH wing only mount*), the strobe light power supply and the wing tip
panels.
The switches and circuit breakers are located at the rear
instrument panel.

PAGE 4
33-41-01 Navigation/Strobe Lights

Refer to Figure 1.
WAR N I N G High Voltage! Wait 5 minutes after shutting off before

starting any work on the strobe light system.
1 Disconnect the battery and wait 5 minutes.
NOTE To change a navigation light bulb or glass the removal

of the Phillips screws (6) is sufficient for access.
2 Remove the lighting unit (1) in combination with the wing

tip panel (2) per Chapter 57.
3 Remove the lighting cover Phillips screws (6).
4 Remove the lighting cover and pull out the strobe light
(7) some centimetres.
5 Remove the lighting unit attachment bolts M4x12/20 (8).
6 Remove the lighting unit.
Silicon between the wing tip panel and the lighting unit.

PAGE 5
33-41-02 Strobe Light Power Supply

Refer to Figure 1.

1 Remove the wing tip attachment plate with the lighting

unit per Chapter 33-41-01 following the steps 1 to 5.
2 Disconnect the electrical wiring of the power supply.
3 Remove the AN 526 C 1032 R8 bolts (9) and discon-
nect the ground bonding lead.
4 Pull out the power supply (10) 2 centimetres and re-
move.
CAUT I O N DC units are polarity sensitive. Black lead is negative.
5 Install in reverse sequence of removal observing Detail

A of Figure 1 when attaching the power supply on the
attachment plate (11).

PAGE 6
Navigation/Strobe Lights Removal/Installation

Figure 1

PAGE 7
EXTRA
Chapter 34
Navigation

PAGE 1
EXTRA Chapter 34
Table of Contents
Chapter Title
34-00-00 GENERAL3
34-10-00 FLIGHT ENVIRONMENT DATA4

34-10-01 Pitot/Static System4
34-10-02 Altimeter5
34-10-03 Airspeed Indicator5
34-15-00 MAINTENANCE PRACTICES6

34-15-01 Pressure Head Removal/Installation6
34-15-02 Pitot Head Attachment Block
Removal/Installation6
34-15-03 Altimeter Removal/Installation7
34-15-04 Airspeed Indicator Removal/Installation7
34-20-00 ATTITUDE AND DIRECTION8

34-20-01 Magnetic Compass8
34-20-02 Turn and Bank Indicator8
34-25-00 MAINTENANCE PRACTICES9

34-25-01 Magnetic Compass Removal/Installation9
34-25-02 Turn and Bank Indicator
Removal/Installation9
34-50-00 DEPENDENT POSITION DETERMINING10

34-50-01 Transponder10
PAGE
PAGE DATE:
DATE:15.
1. December
PAGE 2
EXTRA
34-00-00 GENERAL
The Extra 300L is equipped with an altimeter, an airspeed

indicator and a magnetic compass in the rear cockpit. Optional
a turn and bank indicator is obtainable; in the front cockpit
additionally a second airspeed indicator and altimeter are
installed. The colour markings in instruments follow US-
FAR, part 23 recommendation.
To get the pitot and static pressure a pitot/static head is
installed at the LH wing leading edge.

PAGE 3
EXTRA
34-10-00 FLIGHT ENVIRONMENT DATA
This Section describes that portion of the system which

senses the environmental conditions and uses the data to
influence navigation.
34-10-01 Pitot/Static System
The pitot/static tube is designed to pick up pitot pressure and

static pressure. It is screwed through the L.H. outboard
leading edge into an attachment block located at the rear web
of the main spar. From there the pressures are transmitted by
means of a vinyl tubing which is routed through an aluminium
tube inside the wing to the left side of the fuselage and
further to the instrument panels. The ends of each vinyl tube
are marked with the letters "P" or "S" for pitot resp. static
pressure line. The pitot/static system can be drained by
means of an U-shaped drain which is located at the left side
of the cockpit as shown in Figure 1.
Pitot/Static Drain
Figure 1

PAGE 4
EXTRA FLIGHT ENVIRONMENT DATA
34-10-02 Altimeter
The altimeter is designed to measure pressure changes of the

atmosphere by means of an aneroid capsule, the pressure
changes corresponding to changes in altitude. In this
instrument the shaft of pinion drives via gearwheels the
pointer shaft of the large pointer. Further gearwheels are
used to move the small pointer. The altimeter has a scale
marked in feet (ft.). Three pointers provide an indication of
the altitude; each full turn of the large pointer reads 1,000
feet, each full turn of the middle pointer 10,000 feet. By
turning the knob at the bottom left of the instrument, the
barometric pressure reading is set in millibars.
Barometric range: 946 thru 1050 millibars
Reading range: -1,000 thru 20,000 feet
Temperature range:-55°C thru +70°C
34-10-03 Airspeed Indicator
The airspeed indicator shows the speed of the aircraft relative

to the atmosphere. The pitot airspeed indicator measures the
difference between pitot pressure and static pressure, the
former being picked up by the pitot head at the pitot location
of the air flow and applied to the airspeed indicator via
tubing, the latter also being picked up by the pitot head. The
sensing element of the airspeed indicator is an open
diaphragm which senses internally the pitot pressure and
externally the static pressure, the difference between the
two increasing with increasing speed. This difference
produces distortion of the diaphragm which is translated to
the pointer via a system of levers an gearwheels.
The reading of the airspeed indicator is in knots.
Max. operation altitude: 12,000 m
Operating temperature range: -30°C thru +50°C

PAGE 5
EXTRA
34-15-01 Pressure Head Removal/Installation
The pressure head consists of an inner steel tube, an outer

aluminium tube and a top cap which are screwed.
1 Unscrew the top cap.
2 Unscrew the outer aluminium tube.
3 Unscrew the inner steel tube.
4 Install in reverse sequence of removal applying silicone
in the gap between the outer aluminium tube and the hole
of the wing leading edge.
34-15-02 Pitot Head Attachment Block

1 Remove the Pitot head per Chapter 34-15-01.

2 Remove the wing tip attachment plate with the lighting
unit per Chapter 57-35-01.
3 Disconnect the vinyl tubing.
4 Remove the LN9348-05 stop nuts and the DIN125 M5
washers.
5 Disconnect the ground bonding leads.
6 Remove the attachment block.
7 Install in reverse sequence of removal. Use new stop nuts.

PAGE 6
34-15-03 Altimeter Removal/Installation
1 Remove the instrument cover per Chapter 31-15-01

(rear altimeter only).
2 Remove the vinyl tube and the tube-to-pipe adapter if
necessary.
3 Remove the attachment bolts and nuts.
4 Remove the altimeter.
6 Perform an operation test.
34-15-04 Airspeed Indicator Removal/Installation
1 Remove the instrument cover per Chapter 31-15-01

(rear airspeed indicator only).
2 Remove the vinyl tubing.
3 Remove the attachment bolts and nuts.
4 Remove the airspeed indicator.
5 Install in reverse sequence of removal. Observe correct
installation of vinyl tubing: "Stat. Druck" = static pres-
sure, "Meßdruck" = Pitot pressure.

PAGE 7
EXTRA
34-20-00 ATTITUDE AND DIRECTION
This Section describes that portion of the system which uses

magnetic or inertia forces to sense and display the direction
or attitude of the aircraft.
34-20-01 Magnetic Compass
The magnetic compass shows the course of the aircraft in

relation to magnetic north. Its measuring range is 360° in
increments of 5°. Its case is filled with silicone oil to
dampen the movements. The compass correction card is
located as shown in Chapter 31.
The magnetic compass must be inspected whenever the
engine, magnetizable metals or parts of the electrical resp.
ignition system has been replaced, changed or added,
otherwise per Chapter 05.
The turn and bank indicator indicates the turning rate of the
aircraft about its vertical axis. This instrument comprises an
electrically driven gyro, suspended in a gimbal system and
whose spin axis is parallel to the lateral axis of the aircraft.
The gimbal is connected to the bar pointer of the indicator by
a lever system. This bar pointer also indicates the rate at
which the aircraft is turning.
In addition, the front of the instrument houses a sphere
located in a globe filled with a damping fluid. The change in
this indication shows the pilot whether the aircraft is slipping.

PAGE 8
EXTRA
34-25-01 Magnetic Compass Removal/Installation
1 Remove the instrument cover per Chapter 31-15-01.

2 Remove the compass attachment bolts and nuts.
3 Remove the magnetic compass.
5 Perform a compass compensation and replace the com-
pass correction card.

1 Remove the instrument cover per Chapter 31-15-01.

2 Remove the indicator attachment bolts and nuts.
4 Remove the turn and bank indicator.

PAGE 9
EXTRA
34-50-00 DEPENDENT POSITION DETERMINING
34-50-01 Transponder
Divers transponders can be installed in the EXTRA 300L. A

Transponder is a radio transmitter and receiver that fulfills
the role of the airborne beacon equipment according to the
requirements of the Air Traffic Radar Beacon System
(ATCRBS). It operates on radar frequencies, receiving ground
radar interrogations at 1030 MHz and transmitting a coded
response of pulses to ground-based radar on a frequency of
1090 MHz.
Rermoval/Installation
1 Remove Instrument Cover if transponder has to be

installed from the rear. Refer to Chapter 31-15-01.
2 Remove transponder following the Removal/Installation
Instructions of the respective manufacturer.
PAGE DATE:
DATE:15.
1. December
PAGE 10
EXTRA
Chapter 51
Standard Practices and Structures - General

PAGE 1
EXTRA Chapter 51
Table of Contents
Chapter Title
51-00-00 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
51-00-01 Access Panel Identification . . . . . . . . . . . . . . . . . . . . . . 3
51-10-00 INVESTIGATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
51-10-01 Damage Classification . . . . . . . . . . . . . . . . . . . . . . . . . . 6
51-10-02 Repair Criteria and Limits . . . . . . . . . . . . . . . . . . . . . . . 7
51-30-00 MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
51-30-01 Composite Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
51-30-02 Metal Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
51-30-03 Aluminium Components . . . . . . . . . . . . . . . . . . . . . . . 13
51-60-00 CONTROL SURFACE BALANCING . . . . . . . . . . . 14

51-60-01 Weighing and Determination of
Control Surface Moments . . . . . . . . . . . . . . . . . . . . . . 14
51-70-00 REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
51-70-01 Repair of Reinforced Glass and Carbon Fibre
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
51-70-02 Repair of Sandwich Material . . . . . . . . . . . . . . . . . . . . 20
51-70-03 Repair of Laminates . . . . . . . . . . . . . . . . . . . . . . . . . . 25
51-70-04 Repair of Spars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
51-70-05 Structural Repair of Steel Components . . . . . . . . . . . . 30
51-70-06 Painting of Composite Parts . . . . . . . . . . . . . . . . . . . . 31
51-70-07 Aluminium and Steel Components Refinishing . . . . . . 32

1997 CHAPTER 51
PAGE 2
EXTRA
51-00-00 GENERAL
51-00-01 Access Panel Identification
For the Extra 300L all removable covers and fairings are
defined as access panels (refer to Figure 1 and the adjacent
chart). If maintenance or repair is not restricted to a small
area it is advisable to remove all access panels before
beginning work or checks.
NOTE Access panels partly overlap. Remove the front panels

first.
All panels are screwed.

Prior to unscrewing of the air inlet screen remove bottom
half of the engine cowling not to lose the attachment stopnuts
and washers.
For the removal/installation of the wing tip panels refer to
Chapter 57.
For removal/installation of the main and bottom fuselage
covers refer to Chapter 53.
PAGE DATE: 16.

PAGE January
1. June 2009
1995 CHAPTER 51
PAGE 3
EXTRA GENERAL
SERVICE MANUAL EXTRA 300L Access Panel Identification
Access Panel Identification

Figure 1

PAGE 4
EXTRA GENERAL
SERVICE MANUAL EXTRA 300L Access Panel Identification
Position Item
1 Top half of the engine cowling
2 Oil filler access door
3 Main fuselage cover
4 Instrument cover
5 Tail fairing
6 Tail cone access panel (RH)
7 Tail side skin (LH/RH)
8 Cuff (LH/RH)
9 Wheel speed fairing (LH/RH)
10 Bottom half of the engine cowling
11 Air inlet screen
12 Spinner
From Ser. No 80 item 13 is
13 Exhaust area covering sheet
attached to item 14 by rivets.
14 Bottom fuselage cover
15 LH wing tip panel
16 LH outbourd access panel
17 LH inboard access panel
18 RH inboard access panel
19 RH outboard access panel
22 RH wing tip panel
15.June
PAGE DATE: 1. December
1995 1999 CHAPTER 51
PAGE 5
EXTRA
51-10-00 INVESTIGATION
51-10-01 Damage Classification
WAR N I N G All damage of composite parts must first be classified

by qualified personnel. In case of doubt with regard to
the classification of damage, if a clear definition of the
extent of damage is not possible, or if a repair of dam-
age inspite of the valid manufacturer documentation is
doubtful, contact EXTRA-FLUGZEUGBAU GmbH.
WAR N I N G Only the Damages Classes 2, 3 and 4 may be repaired

by qualified personnel. In case of Damage Class 1 it
has to be contacted EXTRA-FLUGZEUGBAU GmbH.
According to the Luftfahrt-Bundesamt (Federal German

Aviation Authority) four damage classes are defined:
Damage Class 1:
Large scale destruction requiring a partial reconstruction of
the component or large scale repair. Each destruction over
300 mm diameter and each damage of a spar is a large scale
destruction. EXTRA-FLUGZEUGBAU GmbH has to be
contacted prior to repair.
Damage Class 2:
Damage to primary structures and to secondary structures to
the following extent: Holes and fractures extending through
a sandwich component and a scale under 300 mm diameter.
Damage Class 3:
Damage to primary structures and to secondary structures to
the following extent: Small holes or fractures in the external
covering layers, if not accompanied by damage to supporting
layers or internal covering layers.

PAGE 6
EXTRA INVESTIGATION
SERVICE MANUAL EXTRA 300L Damage Classification
Damage Class 4:
Erosion, scratches or nicks not accompanied by fractures or
breakages. Damage to fairings belong to this class.
51-10-02 Repair Criteria and Limits
I M PO R TAN T ll damage of composite parts must first be classified

prior to repair. Refer to Chapter "51-10-01 Damage
Classification".
I M PO R TAN T Only the Damages Classes 2, 3 and 4 may be repaired

by qualified personnel. In case of Damage Class 1 it
has to be contacted EXTRA-FLUGZEUGBAU GmbH.
The decision whether to repair or replace a major unit of

structure will be influenced by factors such as time and labor
available, and by comparison of labor costs with the price of
replacement assemblies. Past experience indicates that
replacement, in many cases, is less costly than major repair.
Certainly, when the aircraft must be restored to its airworthy
condition within limited time, replacement is preferable.

PAGE 7
EXTRA
51-30-00 MATERIALS
This Section describes metallic and non-metallic materials

used in the repair of the Extra 300L and gives the sources of
supply (manufacturers and supplier).
51-30-01 Composite Parts
I M PO R TAN T Only approved materials have to be used for the repair

of composite parts.
Epoxy-system
Manufacturer: RÜTGERS, BAKELITE

Aktiengesellschaft,Varzinerstr. 49,
D-47138 Duisburg 12, Germany
Resin: Rütapox L20
Hardener: Rütapox SL
Ratio of comp.: 100 parts L20 / 34 parts SL (weight ratio)
Glass fibre fabrics
Manufacturer: INTERGLAS, Interglas AG

Söflinger Straße 246, Postfach 3820,
D-89077 Ulm, Germany
WLB-No.* weave weigh
Style US-style
LN 9169 patterns g/m²
90070 8.4505.60 1610 plain 80
92110 8454860 none twill 2/2 163
92125 8455160 none twill 2/2 280
92140 8455160 none twill 2/2 390
*All glass fabric is made of alkali-free E glass with Volan-A

finish or with finish I 550.

PAGE 8
EXTRA MATERIALS
SERVICE MANUAL EXTRA 300L Composite Parts
Carbon fibre fabrics
Manufacturer: CCC, C. Cramer GmbH & Co. KG

Postfach 209,
D-48619 Heek-Nienborg, Germany
Style WLB-No.* weave weight
US-style
CCC DIN 65147 patterns g/m²
447 8,3507;80 none plain 160
452 8,3520;80 none twill 2/2 204
459 - none cross-twill 220
*WLB: Werkstoff Leistungsblatt, according to German

standard DIN-WL
Glass rovings:
Manufacturer: GEVETEX Textilglas-GmbH

Postfach 426,
D-5100 Aachen, Germany
Supplier: Lange & Ritter GmbH
Postfach 100321,
D-7016 Gerlingen, Germany
Type: Vetrotex EC14 - 2400-P185
Carbon rovings:
Manufacturer: Tenax Fibers GmbH & Co. KG

Kasinostr. 19-21
D-42103 Wuppertal
Supplier: Tenax Fibers GmbH & Co. KG
Kasinostr. 19-21
D-42103 Wuppertal
Type: TENAX J HTA 5131 1600tex f24000 t 0
(WLB: 8.3614.85)

PAGE 9
EXTRA MATERIALS
SERVICE MANUAL EXTRA 300L Composite Parts
Core material
a) PVC Foam:
Manufacturer: DIAB
Divincell International Gmbh
Max-von-Laue-Straße 7
D-30966 Hemmingen, Germany
Supplier: see above
Type: Divinycell HT 50
b) Honeycomb:
Manufacturer: EURO COMPOSITES S.A:
B.P.95, Zone Industrielle,
L-6401 Echternach / Luxembourg
Type: ECA-I-R 4.8-29-R
Filler material for resin:
Manufacturer: EBERHARD Chemie GmbH

Olpener Straße 405,
D-51109 Köln 91 (Merheim), Germany
Type: - Cotton flakes
- Microballoons BJO - 0930
Paint:
Manufacturer: GLASURIT GmbH

Max-Winkelmannstr. 80,
D-48165 Münster/Hiltrup, Germany
Supplier: WESSELSAG
Pagenstecherstraße 121,
D-49090 Osnabrück, Germany
Type:
285-100 Glassodur-Rapidfüller AC 85-0100
929-73 Glassodur-MS-Härter SC 29-0173
352-91 Glassodur-Einstellzusatz SV 41-0391

PAGE 10
EXTRA MATERIALS
SERVICE MANUAL EXTRA 300L Composite Part Materials
1006-202/3 Glassit Spritzfüller SP 60-7023

948-36 Glassit Härterpaste, rot SB 48-3360
21- Glassodur-PUR-Acryl-Lack AD/AE 2
51-30-02 Metal Components
I M PO R TAN T Only approved materials have to be used for the repair

of metal components.
Steel tubing (up to Serial No. 44):
Manufacturer: MHP
Mannesmann Hoesch Präzisrohr GmbH
Postfach 1713,
D-59061 Hamm, Germany
Supplier: HEINE+BEISSWENGER Stiftung + CO
Postfach 1510,
D-70705 Fellbach, Germany
Type: WLB 1.7734.4
18mm x 1.0mm, 20mm x 1.0mm,
22mm x 1.0mm, 22mm x 1.5mm,
25mm x 1.5mm
Steel sheet metal (up to Serial No. 44):
Manufacturer: BÖHLER Edelstahl GmbH

München, Germany
Supplier: BÖHLER Edelstahl GmbH
Hansa Allee 321,
D-40549 Düsseldorf, Germany
Type: WLB 1.7734.4
1.0mm, 1.5mm, 2.0mm, 3.0mm

1997 CHAPTER 51
PAGE 11
EXTRA MATERIALS
SERVICE MANUAL EXTRA 300L Metal Components
Steel tubing (from Serial No. 45):
Manufacturer: Pacific Tube Company

5710 Smithway Street
Los Angeles, California 90040, USA
Supplier: Wicks Aircraft Supply, Co.
410 Pine Street
Highland, Illinois 62249, USA
Type: AISI 4130 N (MIL-T-6736 Normalized)
2" x 0.049", 1 1/8" x 0.058", 1" x 0.058"
7/8" x 0.058", 7/8" x 0.035",
3/4" x 0.035", 5/8" x 0.035"
Steel sheet metal (from Serial No. 45):
Manufacturer: Cold Metal Products, Inc.

2301 So. Holt Road
Indianapolis, In. 46241, USA
Supplier: Wicks Aircraft Supply, Co.
410 Pine Street
Highland, Illinois 62249, USA
Type: AISI 4130 N(MIL-S-18729 G Normal-
ized)
0.04", 0.063", 0.08", 0.1", 0.125"
Paint:
Manufacturer: GLASURITGmbH
D-48165 Münster / Hiltrup, Germany
Supplier: WESSELSAG
Type:
801-1552 Glassofix Grundfüller-EP AC 01-1492
965-32/2 Glassofix Härter-EP SC 65-0322

1997 CHAPTER 51
PAGE 12
EXTRA MATERIALS
51-30-03 Aluminium Components
Aluminium sheet metal:
Manufacturer: Kaiser Aluminium & Chem. Corp.

Spokane, Washington
Supplier: Westdeutscher Metallhandel
Postfach 104245
45141 Essen
Type: WLB 3.1364. T3511 or 2024 T3
0.6mm; 0.8mm; 1.2mm
Control rod tubings:
Manufacturer: Aluminium AG
CH-5737 Menziken
Supplier: Karstens & Knauer GmbH&Co
D-28865 Lilienthal
Type: WLB 3.1354. T3
ø 25x1mm
Paint:
Manufacturer: GLASURIT GmbH

D-48165 Münster / Hiltrup, Germany
Supplier: WESSELSAG
Type:
Primer:
283-150 Glassofix-Grundfüller AB83-1150
352-228 Glassofix-Zusatzlösung SC12-0228
Lacquer:

PAGE 13
EXTRA MATERIALS
SERVICE MANUAL EXTRA 300L Aluminium Components
Aluminium hardware metal (brackets, pedestals,

castings, etc.):
Paint:
Manufacturer: Parker & Anchem, Ambler, PA 19002

Supplier: Aircraft Spruce
Chem. coating: Alodine No. 1201 (MIL-C-5541)
Lacquer: see above
PAGE
PAGE DATE: 16.
1. June
January
19952009 CHAPTER
CHAPTER 51
PAGE
PAGE 13A
35
EXTRA
51-60-00 CONTROL SURFACE BALANCING
51-60-01 Weighing and Determination of Control

Surface Moments
All weighing of control surfaces is performed with surface

removed from aircraft. Weighing and determination of con-
trol surfaces moments is necessary after repairs or painting.
Weigh the control surfaces including the mass balances in
disassembled condition. The aileron weight includes the
spade. Copy page 31, enter the values (W, m, r) there and
check whether the surface weights or moments are within
the given tolerances. If they are not, contact the manufac-
turer for advice.
For the determination of control surface moments follow
the steps as described below and use two balancing mandrels
like shown in the Figure 2:
Balancing Mandrels
Figure 2
Procedure
1 Remove the control surface (refer to chapter 27).

2 Reinstall the bolts in two brackets.

PAGE 14
EXTRA CONTROL SURFACE BALANCING
SERVICE MANUAL EXTRA 300L Weighing and Determination of Control Surface Moments
3 Put the control surfaces on the balancing mandrels (use

a wire for the trim tab).
4 Weigh by means of a conventional spring balance (kg/g-
indication) at the given weighing points (Figure 3) and
enter the weight (m) in Figure 4.
5 Measure distance of hinge center line to weighing
point (r) and enter the value in Figure 4.
6 Calculate the control surface moment (M) in Figure 4.
I M PO R TAN T If values exceed the given tolerances in Figure 4 contact

the manufacturer before beginning any changes of con-
trol surfaces.
7 Reinstall the control surfaces.
1. June
1996 CHAPTER 51
PAGE 15
Determination of Control Surface Moments

Figure 3

PAGE 16
Permissible Weights and Moments

250
Elevator
(incl. mass balance)
200
Rudder
(incl. mass balance)
150
Aileron
100 (incl. mass balance and spade)
50
0
5 5.5 6 6.5 7 7.5
Mass (kg)
3.5
3
2.5
Trim tab
2
1.5
1
70 80 90 100 110 120 130 140
Mass (g)
Weights
Aileron LH: (W) . . . . . . . . . . kg

Aileron RH: (W) . . . . . . . . . . kg
Rudder: (W) . . . . . . . . . . kg
Elevator: (W) . . . . . . . . . . kg
Trim Tab: (W) . . . . . . . . . . kg
Moments
Aileron LH: (m:) . . . . . . . kg . 9.81m/s2 . (r:) . . . . . . . cm = (M:) . . . . . . . . . . Ncm

Aileron RH: (m:) . . . . . . . kg . 9.81m/s2 . (r:) . . . . . . . cm = (M:) . . . . . . . . . . Ncm
Rudder: (m:) . . . . . . . kg . 9.81m/s2 . (r:) . . . . . . . cm = (M:) . . . . . . . . . . Ncm
Elevator: (m:) . . . . . . . kg . 9.81m/s2 . (r:) . . . . . . . cm = (M:) . . . . . . . . . . Ncm
Trim Tab: (m:) . . . . . . . kg . 9.81m/s2 . (r:) . . . . . . . cm = (M:) . . . . . . . . . . Ncm
Control Surface Weights and Moments
Figure 4
15.June
1995 1999 CHAPTER 51
PAGE 17
EXTRA
51-70-00 REPAIRS
51-70-01 Repair of Reinforced Glass and Carbon

Fibre Components
I M PO R TAN T Repair of composite parts has to be carried out only by

qualified and authorized personnel.
If the aircraft is damaged, proceed as follows. First conduct

a careful visual inspection of the surface and the damaged
area. Frequently, the damage extends to futher components,
sometimes a fracture will continue invisible beneath the
surface.
Perform the repair work with utmost care. The external shell
of the wing and empannage is stressed; a failure of this
bonded structure can lead to an aircraft crash. In order to
eliminate dangerous stress concentrations, avoid changes in
cross-sectional areas.
I M PO R TAN T The resin-hardener mixture ratio must be precisely

maintained (+0.5%). Clean cups and tools must be used.
The weight ratio of glass fabric to resin mixture should
be approximately 50:50.
Immediately prior to applying the wet laminate, sand and

vacuum clean the repair area, so that no dirt and dust is
involved which could prevent a secure adhesion.
WAR N I N G Sanding carbon and glass fibre laminates gives off a fine
dust that may cause skin and/or respiratory irritation
unless suitable skin and resiration protection is used.
WAR N I N G Carbon-tetracloride or Acetone used for cleaning re-

pair areas are flamable liquids and should be used with
proper ventilation and safety equipment.
I M PO R TAN T As with plywood grain, the direction of the various fi-

bres (longitudinal or diagonal) is of great importance
for the stability.

PAGE 18
EXTRA REPAIRS
SERVICE MANUAL EXTRA 300L Repair of Reinforced Glass and Carbon Fibre Components
The number of layers required to restore the stability in the

damaged area can be taken from the layer sequence/place-
ment plan.(Refer to the respective Chapters)
It is necessary to know the number and direction of layers in
the damaged area, in order to be able to replace them with the
original number. In all cases, the thickness of the laminate
has to be measured with a vernier calliper for the exact
determination of the laminate tickness.
One technique to learn about the number of layers is to burn
a small piece taken from the damaged area. The resin will
burn off, leaving the glass and/or carbon fabric to be in-
spected for the number of layers and the type of fabric.
Creating a scarfed overlap takes time. Sand away as much of
the old material, that the new fabric patches do not project
beyond the contour.
In order to shorten the curing time, a heater can be used to
increase the ambient temperature.
CAUT I O N Too high temperature will cause large air bubbles in

the laminate. Local overtemperature can be prevented
by using a foil tent which leads the hot air stream.
The curing cycle must be maintained as stated. Use a

thermometer to monitor the temperature.
I M PO R TAN T After repair of control surfaces, check for proper bal-

ance ( refer to chapter 27, Flight Controls).
It is recommended to prepare test specimens at the same

time as the actual repair is accomplished. These can then be
subject to a material test to establish the quality of the
laminate in the repaired part. To make this determination
valid, the specimens must be assembled with the same style
of fabric and resin mixture. Subsequently the specimens
must be subject to the curing pressure, temperature and time
identical with those in the actual repair.

PAGE 19
EXTRA REPAIRS
51-70-02 Repair of Sandwich Material
Two types of core materials are used for sandwich on the

EXTRA 300L:
- PVC hard foam
- Honeycomb
both with glass or carbon fibre shells
The following section describes the repair of both types of
sandwich. Different processing techniques for these mate-
rials, if necessary, are also described.
a) Minor surface damage
Around a visible crack, the laminate may be separated from

the core material. Determine the extent of this area by coin
tapping. Remove the separated laminate carefully using a
sanding disk, sanding block or a sharp knife. Prepare a
scarfed overlap of the laminate around the damaged area.
Overlap lenght per fabric layer min. 20 mm;
I M P O R TAN T Ratio (laminate thickness : overlay lenght) min. 1: 50

(refer to Figure 5).
Minor surface damage

Figure 5
After preparing the scarfed overlap, clean the repair area

thoroughly as follows:
- Remove the sanding dust with a pneumatic vacuum
cleaner
- Clean the scarfed overlaps with carbon-tetrachloride or
acetone in case of dirt or grease was introdued during the
preparation.
Damaged core material has to refilled with a mixture of resin
and microballoons (weight ratio 100:15). Apply resin mixture

PAGE 20
EXTRA REPAIRS
SERVICE MANUAL EXTRA 300L Repair of Sandwich Material
to the repair area and lay on fabric in accordance to the layer

sequence plans. Ensure to use correct style and direction of
fabric.
I M PO R TAN T Repair area must be clean of dirt, dust and grease!
Lay out the required number and size of fabric pieces on a

piece of colored plastic foil and soak (wet) them with resin
mixture, subsequently position them on the repair area.
I M PO R TAN T Remove the plastic foil after each positioning process.
For a repair of honeycomb sandwich parts you have to

observe the following: The repair area has to be cured under
condition of vacuum bagging.
For vacuum bagging, proceed as follows:
- Apply peel nylon fabric on the last repair fabric layer
- Perforate a clean, thin plastic foil with a thick needle
(max.spacing of holes: 20mm x 20mm) - mainly in the
area of the honeycomb - and lay it on the repair area.
- Lay a jute cloth (weave) or equivalent bleeder cloth on
this perforated plastic foil.
- Lay an air tight plastic foil upon the jute weave and seal
their edges to the surrounding surface using an adhesive
tape.
- Apply suction with a vacuum pump (pressure approx.
0.7 bar/ 10 psi)
- Apply the thermal curing cycle.(Refer to Figure 3)
- Following the curing cycle remove vacuum bagging
material and peel nylon fabric.
After the pre-curing period at room temperature, the re-
paired area has to be cured according the temperature cycle
as shown on Figure 6.

PAGE 21
EXTRA REPAIRS
Curing cycle resin L20/SL

Figure 6
After the curing process is completed, the repair area can be

sand level to the surrounding area.
CAU T I O N Sand only the edge thickness of repair laminate (refer

to Figure 7)!
Level Sanding of Surrounding Area

Figure 7
NOTE For painting of the repair area refer to Chapter 51-70-

06.
b) Damage of complete sandwich
If the inner laminate is also damaged, first remove the upper

laminate within the area, where no secure bond connection
to the core material is suspected. Trim out the complete
damaged portion of core material to a circular or elliptical
shape.

PAGE 22
EXTRA REPAIRS
The damaged area of the inner laminate has to be taken out as

well. Make sure not to increase the disbond area by preparing
the hole. Preferably use a hand held milling machine. In case
of cutting with a saw, the pulsation stress may peel of the
inner laminate (secondary damage). If the extent of the
disbonded area on the inner laminate exceeds the prepared
cut out, increase the cut out of material and upper laminate.
Prepare a scarfed overlap of laminate around the circular cut
out. Overlap lenght of inner laminate should not be less than
20 mm.
I M PO R TAN T Overlap lenght of the upper laminate should not be less

than 1/50; (ratio: laminate thickness / overlap lenght).
Prepare a replacement block of core material (foam or

honeycomb) with equivalent diameter and thickness. Cut it
to fit snuggly in the trimmed hole. In case of foam core, coat
one side with a mixture of resin and microballoons (ratio
100:15). Apply prelaminated fabric layers required for the
inner laminate on this side of the core filler block. Ensure
correct style and direction of fabric. After precuring the
laminate at elevated room temperature (30°C), scarf the
overlap and sand the upper overlapping core material down,
up to the surrounding core material.
Subsequently clean the repair area thoroughly as follows:
cleaner
preparation.
WAR N I N G Carbon-tetracloride or Acetone used for cleaning re-

pair areas are flamable liquids and should be used with
proper ventilation and safety equipment.
I M PO R TAN T Repair area must be free of dirt and grease.
Wet all surfaces of the backing plate and the scarfed area with
resin mixture. Lay on prelaminated fabric layer in accordance
to the layer sequence plan. Ensure correct style and direction
of fabric.

PAGE 23
EXTRA REPAIRS
Damage of Complete Sandwich

Figure 8
Lay out the required number and size of fabric pieces on a

piece of plastic foil and wet them with resin mixture.
Subsequently position them on the repair area.
The repair area has to be cured under condition of vacuum

bagging. Proceed as follows:
(max. spacing of holes: 20mm x 20mm) - mainly in the
- Lay a jute cloth or equivalent bleeder cloth on this
perforated plastic foil
- Lay a second plastic foil uppon the jute weave and seal
tape.
- Apply suction with a vacuum pump (pressure approx.
0.7bar / 10psi)
- Apply the thermal curing cycle
- Following the curing cycle carefully remove vacuum
bagging material and peel nylon fabric.
NOTE After the pre-curing period at room temperature, the

repaired area has to be cured according the tempera-
ture cycle as shown on Figure 6.

I M PO R TAN T Sand only the edge thickness of repair laminate!

PAGE 24
EXTRA REPAIRS
For painting of the repair area proceed like mentioned in

Chapter 51-70-06.
51-70-03 Repair of Laminates
a) Minor damage
Scarf the edges of the minor damage area with sandpaper.

Minimum lenght of scarf per fabric layer approx. 20 mm;
ratio (laminate thickness : scarf lenght) approx. 1: 50.
Following the scarf procedure, clean the repair area thor-
oughly:
cleaner
preparation.
CAUT I O N Repair area must be free of dirt, dust and grease.
Wet the prepared scarfed areas with resin mixture. Lay on

prelaminated fabric layer in accordance to the layer se-
quence plan. Ensure correct style and direction of fabric.
Apply peel nylon fabric on the last repair fabric layer.
NOTE Lay out the required number and size of fabric pieces
on a piece of colored plastic foil and wet them with
resin mixture. Subsequently position them on the repair
area.
After the curing process is completed, remove the peel

nylon fabric. The repair area can be sand level with the
surrounding area.
CAUT I O N Sand only the edge thickness of repair laminate!
Refinish the surface according chapter 51-70-05 Painting.

PAGE 25
EXTRA REPAIRS
SERVICE MANUAL EXTRA 300L Repair of Laminates
If the extent of the damaged area exceed 10 cm (4 inches) a

large damage repair is required.
Carefully trim out the damaged portion to a circular or oval
shape.
Prelaminate a backing plate from two layers of glass fibre
fabric and resin mixture, which must be approx. 20 mm
larger than the damaged area. Apply peel nylon fabric as
external layer. Sandwich the resin wetted layers between two
sheets of plastic foil.
Work the excess resin out and allow the plate to cure at
elevated room temperature for 8 hours on a flat surface or a
plasticfoil-covered surface of the proper curvature near the
damaged area, or the same location on a comparable
undamaged part.
Following the curing cycle remove plastic foil and peel
nylon fabric. Bond the backing plate to the inside using a
mixture of resin and cotton flocks, and adapt to the contour.
Cure the bonding at elevated room temperature for 8 hours.
Subsequently scarf the edges of the damaged portion with
sandpaper. Minimum lenght of scarf per fabric layer approx.
20 mm;
I M PO R TAN T Ratio (laminate thickness : scarf lenght) approx. 1: 50.

oughly:
cleaner
preparation of the overlap.
I M PO R TAN T Repair area must be free of dirt, dust and grease.
resin mixture. Lay on prelaminated fabric layer in accord-
ance to the layer sequence plan. Ensure correct style and
direction of fabric.

PAGE 26
EXTRA REPAIRS
area.

Repair of minor damage

Figure 9
b) Large damage
If the extent of the damaged area exceed 10 cm (4 inches) a

large damage repair is required.
Carefully trimm out the damaged portion to a circular or oval
shape.
Prelaminate a backing plate from two layers of glass fibre
fabric and resin mixture, which must be approx. 20 mm
larger than the damaged area. Apply peel nylon fabric as
external layer. Sandwich the resin wetted layers between two
sheets of plastic foil. Work the excess resin out and allow the
plate to cure at elevated room temperature for 8 hours on a
flat surface or a plasticfoil-covered surface of the proper
curvature near the damaged area, or the same location on a
comparable undamaged part.
Following the curing cycle remove plastic foil and peel
nylon fabric. Bond the backing plate to the inside using a
mixture of resin and cotton flocks, and adapt to the contour.
Cure the bonding at elevated room temperature for 8 hours.

PAGE 27
EXTRA REPAIRS
Subsequently scarf the edges of the damaged portion with

sandpaper. Minimum lenght of scarf per fabric layer approx.
20 mm;
I M PO R TAN T ratio (laminate thickness : scarf lenght) approx. 1: 50.

oughly:
cleaner
preparation of the overlap.
I M PO R TAN T Repair area must be free of dirt, dust and grease.
resin mixture. Lay on prelaminated fabric layer in accordance
to the layer sequence plan. Ensure correct style and direction
of fabric.
area.

- Apply peel nylon fabric on the last repair fabric layer.

PAGE 28
EXTRA REPAIRS
- Perforate a clean, thin plastic foil with a coarse needle

area of the honeycomb - and lay it on to the repair area.
- Lay a jute cloth or equivalent bleeder cloth on this
perforated plastic foil.
- Lay an air tight plastic foil upon the jute weave and seal
tape.
- Apply suction with a vacuum pump (pressure difference
approx. 0.7bar / 10psi)
- Curing cycle
- Following the curing cycle carefully remove vacuum
bagging material and peel nylon fabric.
After the pre-curing period at room temperature, the re-
paired area has to be cured according the temperature cycle
as shown on Figure 3.
CAUT I O N Sand only the edge thickness of repair laminate!
Refinish the surface according chapter: 51-10-09 Painting.
51-70-04 Repair of Spars
The spars consists of carbon roving caps, glass or carbon

fibre webs and PVC foam cores.
I M PO R TAN T The spars are higly stessed; a failure of this bonded struc-
ture can result in loss of the aircraft! In all cases, the
repair of a spar must be considered as a large-scale re-
pair with a Damage Class 1 (Refer to Chapter 51-10-01
Damage Classification"). EXTRA-FLUGZEUGBAU
GmbH has to be contacted prior to repair!

PAGE 29
EXTRA REPAIRS
51-70-05 Structural Repair of Steel Components
Restoration of a damaged fuselage to its original design

strength, shape and alignment involves careful evaluation of
the damage, followed by exacting workmenship in performing
the repairs.
I M PO R TAN T Should structural repairs practicable on the aircraft

be necessary, refer to "Aircraft Inspection and Repair
FAA AC 43.13-1A" and "Aircraft Alterations Accept-
able Methods, Techniques and Practices FAA AC 43.13-
2A".
I M PO R TAN T Alterations or repair of the airplane must be accom-

plished by licensed personnel. Consult EXTRA-
FLUGZEUGBAU GmbH in case of doubt about a re-
pair not specifically mentioned there.
Consider, that up to Serial No. 44 WLB 1.7734.4 type steel

has been used for the complete fuselage structure so as steel
tubes, brackets, connections etc. (steel tubes are in mm-
measurements). From Serial No. 45 AISI 4130 N type steel
is used (steel tubes are in inch-measurements). Also refer to
Chapter 51-30-02.
The two steel types shall not be mixed in repair.
NOTE If welding work must be performed, use only the TIG

procedure (Tungsten Inert Gas). Use steal welding wire
1.7734.2 (up to Serial No. 44) or 1.7324, 1.7734.2 or
equivalent (from Serial No. 45) for welding additive.

1997 CHAPTER 51
PAGE 30
EXTRA REPAIRS
51-70-06 Painting of Composite Parts
WAR N I N G Coating materials may cause sensitization by inhala-

tion and skin contact. Hardeners and coating materials
ready for use can have an irritant and sensitizing effect
upon the skin and respiratory tracts and cause allergic
reactions.
WAR N I N G Provide for a continuous supply of fresh air during and

also after the application, do not inhale the vapours and
wear a breathing mask during the spray application of
these materials. Persons suffering from an allergy or
being prone to diseases of the respiratory tracts must
not get in contact with coating materials.
Refer to the manufacturer technical information sheet!!
After curing cycle the surface of repared area can be sanded

with sandpaper (80 grade). Indentations are filled with white
polyester filler. Subsequently achieve a surface as uniformly
rough as possible using a finer dry sandpaper (150 or 320
grade). Prior to paint application, the surface of the repair
area must be cleaned thoroughly of all sanding dust, separation
compounds and other foreign materials. Subsequently apply
Glassodur Rapid Filler with a spray gun.
NOTE The Rapid Filler must be completely dry before the cov-
ering paint can be applied.
For the final sanding, use 400 grade wet sandpaper to achieve
a smooth clean surface. Allow surface to dry. Paint application
of Glassodur-Pur-Acryl-Lack AD/AE 21 two component
acryl paint is performed with a spray gun.
Paint can be mixed with small quantities of reducer. After
completion of the painting, polish the repair area.

PAGE 31
EXTRA REPAIRS
51-70-07 Aluminium and Steel Components

Refinishing
Complete procedure necessary to remove existing paint

from aluminium and steel components and then to repaint
them as described in the following paragraphs.
Degreasing
WAR N I N G Cleaning solvents can be toxic and volatile. Use only in

well ventilated areas. Avoid physical contact with sol-
vent and do not inhale vapors. Keep solvent containers
covered when not in use.
CAUTI O N Before stripping parts, remove all fittings, O-rings,

nuts, bolts, washers, pistons, bearingcups, etc.
1 Clean all metal parts by immersing in a clean degreasing

solution. An alkaline based solution is recommended for
aluminium and magnesium parts.
2 Hardened dirt or grease may be removed with soft bris-
tle brush, or by soaking in cleaning solution.
3 Where necessary clean bearing cones carefully in a
separate container of clean solvent.
CAUT I O N Do not spin bearing cones with compressed air.
4 After cleaning, thoroughly dry all metal parts with fil-

tered, dry compressed air.
5 It is recommended that all O-rings, backup rings, and
wipers be replaced at each overhaul. However, if neces-
sary, O-rings may be reused, but should be put back into
position from which removed.
6 Wipe down O-rings, backup rings, wipers, or other rubber
parts with a clean dry cloth. Lubricate with a suitable O-
ring lubricant prior to installation.

PAGE 32
EXTRA REPAIRS
SERVICE MANUAL EXTRA 300L Aluminium and Steel Components Refinishing
Paint Removal
Disassemble components to the level required for repaint-

ing, then proceed as follows.

CAUTI O N Before stripping parts, remove all fittings, O-rings,

nuts, bolts, washers, pistons, bearingcups, etc. Parts
must be totally immersed in solvent, to maximize
cleaning.
1 Degrease part per degreasing paragraph.

2 Totally immerse part in paint removing solvent. Portions
not totally covered by solvent will begin to corrode.
NOTE Stripping agents are commercially available for remov-

ing topcoat and primer. Follow manufacturer's recom-
mendations for use and disposal of stripping solutions.
3 Remove part from solvent and rinse thoroughly with

water heated to 160° to 180°F (71° to 82° C). Flush
solvent from all cavities and threaded holes where en-
trapment might occur
4 Thoroughly dry part with filtered, dry compressed air.
5 Where applicable refer to inspections procedures given
in the respective chapters for specific parts to locate
possible defects.
NOTE Refinishing should be completed as soon as possible;

unprotected parts will begin to corrode.

PAGE 33
EXTRA REPAIRS
SERVICE MANUAL EXTRA 300L Aluminium and Steel Components Refinishing
Repainting
Paint all surfaces exept those which are subjected to friction

(bearing surfaces, anchor bolt bores, etc.). Proceed as
follows:
1 Parts to be repainted should be cleaned and stripped per
instruction in degreasing and paint removal paragraphs.
2 Aluminium parts should have a protective barrier be-
tween the topcoat and base metal. It is recommended
they be treated with solutions listed in Chapter 51-30.
3 Apply solution liberally and evenly. Allows it to set from
1 to 5 minutes. The solution must completely wet the
surface and overlap onto the adjoining anodize.
4 Remove excess coating by flushing with clean water.
5 Paints parts with one coat of wash primer. Allow to dry
thoroughly.
6 Paint parts with one coat of lacquer listed in Chapter
51-30. Allow to dry thoroughly before reassembly.

PAGE 34
EXTRA
Chapter 53
Fuselage

PAGE 1
EXTRA
Table of Contents
Chapter Title
53-00-00 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
53-00-01 Canopy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
53-00-02 Canopy Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
53-00-03 Main Fuselage Cover . . . . . . . . . . . . . . . . . . . . . . . . . . 14
53-00-04 Bottom Fuselage Cover . . . . . . . . . . . . . . . . . . . . . . . . 14
PAGE DATE:
DATE: 16.
1. June
January
1995
2009 CHAPTER 53
PAGE 2
EXTRA
53-00-00 GENERAL
The fuselage structure of the EXTRA 300L consists of a

TIG-welded steel tube construction integrating the wing and
empennage connections (refer to Figure 1).
The particular areas of the fuselage are covered with different
materials (also refer to Chapter 51-00-01 "Access Panel
Identification"): Both halves of the engine cowling consist
of glass fibre laminate and honeycomb. The main fuselage
cover consists of glass fibre, carbon fibre and aramid laminate.
The bottom fuselage cover is made of carbon fibre and
aramid fibre laminate, the cuffs of carbon fibre laminate. The
lower rear part of the fuselage is covered with fabric. The
window portion is of acrylic glass. The tail fairing consists
of glas fibre laminate and the tail side skins are made of
aluminium sheet metal. The layer sequences of the composite
parts are shown in Figures 2-6.
All composite parts, as protection against moisture and UV
radiation, are coated with an unsaturated polyester gel-coat,
an acrylic filler and finally with an acrylic paint.
For repair of composite parts and steel components refer to
Chapter 51. The repair of fabric has to be executed in
accordance to the FAA AC 43.13-1A.

PAGE 3
EXTRA GENERAL
Fuselage Steel Tube Design

Figure 1

PAGE 4
EXTRA GENERAL
Layer Sequence Top Half of the Engine Cowling

Figure 2

PAGE 5
EXTRA GENERAL
Layer Sequence Bottom Half of the Engine Cowling

Figure 3

PAGE 6
EXTRA GENERAL
Layer Sequence Main Fuselage Cover up to Ser. N° 10

Figure 4, Sheeet 1

PAGE 7
EXTRA
Layer Sequence Main Fuselage Cover from Ser. N° 11

Figure 4, Sheeet 2

PAGE 8
EXTRA GENERAL
Layer Sequence Bottom Fuselage Cover and Cuffs

Figure 5

PAGE 9
EXTRA GENERAL
Layer Sequence Tail Fairing up to Ser. No. 51

Figure 6, Sheet 1
Layer Sequence Tail Fairing from Ser. No. 52

Figure 6, Sheet 2
1. June 1995 1999 CHAPTER 53
PAGE 10
EXTRA
53-00-01 Canopy
1 Open canopy.
CAUT I O N Support the canopy by hand before disconnecting the

opening limiter strap.
2 Remove the attachment bolt of the opening limiter strap.

3 Push canopy to front and remove.
53-00-02 Canopy Glass
Replacement
1 Remove canopy per Chapter 53-00-01.

2 Remove the old canopy glass.
3 Gently remove remaining glue with a chisel.
4 Sand down the bonding area on the canopy frame
completely (sandpaper grit/P120). Check that there are
no reflecting areas left.
Canopy Frame
2 – 4 mm
Canopy Glass
Positioning Line
Typical cross section of canopy bonding area

Figure 7
5 Fit the new canopy glass in the canopy frame. Opening

between canopy glass and canopy frame about 2-4mm.
PAGE DATE:
DATE: 16.
1. June
January
1995
2009 CHAPTER 53
PAGE 11
EXTRA
Position markings
Position markings
Canopy Position Markings

Figure 8
6 Secure the canopy glass in the frame. Draw a positioning

line (see figure 7) and position markings on the inside
(see figure 8).
7 Prepare canopy glass for bonding.
8 Remove a strip (width approx. 50mm) from the protec-
tive layer from the outside along the canopy glass
bonding area.
9 Place fine tape (width 3mm) on the outside opposing
the positioning line on the inside.
10 For protection purposes, place 3 layers of tape as de-
picted in figure 9.
11 Sand down the canopy glass up to the fine tape line (use
Scotch Brite Handpad Medium). Check that there are
no reflecting areas left.
50 mm Tape
2 x 20 mm Tape
Canopy Glass
Fine Tape
Bonding Area Inside Line
Canopy Tape Markings

Figure 9
PAGE DATE:
DATE:16. January
1. June 2009
1995 CHAPTER 53
PAGE 12
EXTRA
Filler
B
A
Canopy adhesive remainders

Figure 10
12 Remove the fine tape.

13 Prepare adhesive (3M Scotch-Weld Urethane Adhesives
3549 B/A): Thoroughly mix approx. 300 g (approx. 10.6
oz.) adhesive (weight ratio white base : brown accelera-
tor - 100 : 109, 40-70 minutes application time at RT).
Mix approximately 15 seconds after a uniform color is
obtained.
14 Put adhesive on the bonding area. For maximum bonding
strength, apply product to both canopy glass and canopy
frame.
15 Place canopy glass in canopy frame. Observe correct
position using position markings.
16 Apply pressure on canopy glass using tightener to hold
it in place.
17 Remove adhesive remainders with wooden spatula.
18 Curing time: min. 75 °F 8h
68 °F 15h
19 The next day: Remove tightener and remove canopy from
form.
20 Sand down (using Scotch Brite Handpad Fine) a small
area around the outside edge between canopy frame and
canopy glass (area A in figure 10).
21 Apply primer (EP801-1552, curing time: 24h) before
applying filler (Glasurit 839-53) and refinish the area.
Make sure, the filler does not get in contact with

CAUT I O N
untreated canopy glass.
PAGE DATE:
DATE: 16. January
1. June 2009
1995 CHAPTER 53
PAGE 13
EXTRA
22 Sand down (using Scotch Brite Handpad Fine) the

overlapping part between canopy glass and canopy frame
on the inside (Area B in figure 10).
23 Apply primer (Glasurit 934-0) and refinish the area
(Nextel).
53-00-03 Main Fuselage Cover
1 Remove the canopy per Chapter 53-00-01.

2 Disconnect the pitot hoses from the front instruments.
3 Remove the instrument cover per Chapter 31.
4 Remove the rear canopy hinge.
5 Remove the filler neck attachment screws.
6 Remove the main fuselage cover attachment screws.
7 Remove the main fuselage cover.
53-00-04 Bottom Fuselage Cover
Removal
1 Remove cowling and landing gear cuffs as per Chapter

51-00-01.
2 Remove main fuselage cover as per Chapter 53-00-03
2 Remove bottom fuselage cover by removing the
attachment screws.
PAGE DATE:
DATE: 16.
1. June
January
1995
2009 CHAPTER 53
PAGE 14
EXTRA
Installation
I M PO R TAN T The cockpit area must be thoroughly sealed and thus

separated from the engine compartment. Gases or fluids
could get into the cockpit area.
Critical areas to be observed are the following:

Position A and D of Figure 1A, where different parts converge
(firewall, aluminium profile, bottom fuselage cover and
exhaust area covering sheet)
Position B and C, where a bent corner ends in a bore hole.
Forward View on Bottom Side Firwall

Figure 1A
1 Position bottom fuselage cover in its original position

and install attachment screws.
2 Install bottom cowling attachment screws (one on either
side) without cowling present (see two outer circles in
Figure 1A).
3 Loosen clamp screws on gascolator drain and fuel pump
vent lines for easy access (see inner dotted circles).
4 Prepare PR-812 firewall sealant by mixing brown part
A with black part B with weight ratio 2.5:100.
5 Clean areas (from inside and outside) with solvents at
four positions pointed out by the arrows in Figure 1A.
Immediately thereafter, dry these areas with a new dry
cloth.
6 At the gascolator drain (position A) seal the remaining
gap between firewall and bottom fuselage cover from
inside and outside with PR-812 firewall sealant.
PAGE
PAGE DATE: 16.
1. June
January
19952009 CHAPTER 53
PAGE 15
EXTRA
Minimum sealant thickness approximately 1/8 inch

(= 3 mm).
7 Repeat step 6 at positions B, C and D.
8 Cure for at least 24 hours at room temperature.
9 Fasten clamp screws on gascolator drain and fuel pump
vent lines.
10 Remove the two bottom cowling attachment screws.
11 Reinstall main fuselage cover as per Chapter 53-00-03
12 Reinstall landing gear cuffs and engine cowling as per
Chapter 51-00-01.
PAGE DATE:
DATE: 16.
1. June
January
1995
2009 CHAPTER 53
PAGE 16
Chapter 55
Stabilizers

PAGE 1
Table of Contents
Chapter Title
55-00-00 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

55-21-01 Horizontal Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
55-21-02 Vertical Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

PAGE 2
55-00-00 GENERAL
The EXTRA 300L has a conventional empennage with stabi-

lizers and moveable control surfaces. The spars consist of
carbon roving caps, glass fibre webs and PVC foam cores.
The shells are built of honeycomb sandwich with glass fibre
laminate. Also buckling is prevented by plywood ribs.
Deviating from this, the elevator is constructed in the same
manner as the ailerons (refer to Chapter 57). On the R/H
elevator half a trim tab is fitted with two hinges.
The layer sequences of the stabilizers, the elevator and the
rudder are shown in Figures 1-4.
For repair of composite parts refer to Chapter 51.

PAGE 3
Layer Sequence Horizontal Stabilizer

Figure 1

PAGE 4
Layer Sequence Elevator

Figure 2

PAGE 5
Layer Sequence Vertical Stabilizer

Figure 3

PAGE 6
Layer Sequence Rudder

Figure 4

1997 CHAPTER 55
PAGE 7
55-21-01 Horizontal Stabilizer
Removal
Remove elevator and rudder per Chapter 27-31-01, remove

the vertical stabilizer per Chapter 55-21-02 and then reverse
procedure of installation.
Installation
CAUT I O N Make shure that the trim bowden cable will not be dam-
aged when installing the horizontal stabilizer.
1 Slide the horizontal stabilizer with its front spar

(1, Figure 5) into the attach brackets (4) on fuselage.
The rear spar (2) is situated behind the rear attachment
bracket (5). (Trim tab is on the right side.)
2 Slide in LN 9037-10054 front spar attachment bolts (8)
with an additional DIN 125 M10 washer under bolt head
from the front to the rear. These bolts are also used for
the vertical stabilizer attachment. So do not apply stop
nuts before the vertical stabilizer is fitted to the fuselage.
3 Slide in the rear spar attachment bolts (7) from front to
rear. Use LN 9037-08042 bolts in connection with LN
9348-08 stop nuts and DIN 125 M8 washers up to Se-
rial No. 44. From Serial No. 45 use LN 9037-10042
bolts in connection with LN 9348-10 stop nuts and DIN
125 M10 washers. Torque nuts for fastening.
4 Fasten the ground bonding lead (3) by means of the DIN
933 M5x12 bolt (6), the DIN 125 M5 washers and the
LN 9348-05 stop nuts.
5 Follow the procedure of Vertical Stabilizer Installation
(refer to Chapter 55-21-02).

1997 CHAPTER 55
PAGE 8
SERVICE MANUAL EXTRA 300L Horizontal Stabilizer
Horizontal Stabilizer Removal/Installation

Figure 5

PAGE 9
55-21-02 Vertical Stabilizer
Removal
1 Remove the tail fairing and the tail cone access panel
3 Remove the bottom hinge bracket assembly per Chap-
ter 27-21-02.
4 Remove the two LN 9348-10 stop nuts (2, Figure 6)
and DIN 125 M10 washers of the front main bolts.
5 Remove the rear LN 9037-10054 main bolt (3) with
the DIN 125 M10 washers and the LN 9348-10 stop
nut.
CAUT I O N Do not put the fin too far backward, the antenna could
be damaged.
6 Put the fin backward and lift the fin over the antenna.
Installation
1 Put the vertical stabilizer leading edge over the antenna.
CAUT I O N Do not put the fin too far backward, the antenna could
be damaged.
2 Slide the auxiliary spar attachment sheet (1, Figure 6)

of the vertical stabilizer from the rear over the
preinstalled horizontal stabilizer front spar bolts and
install the DIN 125 M10 washers and LN 9348-10 stop
nuts (2).
3 Insert the LN 9037-10054 bolt (3) to the main spar from
rear to front. Use LN 9348-10 stop nuts and DIN 125
M10 washers.
4 Install the bottom hinge bracket to the tail per Chapter
27-21-02.
5 Reinstall the tail fairing, the tail side skins and the tail
cone access panel per Chapter 51-00-01.

PAGE 10
SERVICE MANUAL EXTRA 300L Vertical Stabilizer
Vertical Stabilizer Removal/Installation

Figure 6

PAGE 11
Chapter 57
Wings

PAGE 1
Table of Contents
Chapter Title
57-00-00 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

57-05-01 Wing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

57-35-01 Wing Tip Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
57-60-00 AILERONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
PAGE DATE: 1. June

June 1995
1997 CHAPTER 57
PAGE 2
57-00-00 GENERAL
The wing consists of a one-piece, dual chamber main spar

with carbon fibre roving caps and carbon fibre webs. For the
spar core PVC foam is used. The wing shells are a honeycomb
sandwich construction with carbon fibre laminates. To pre-
vent buckling of the shells, plywood ribs are used.
The layer sequence of the wing is shown in Figure 1.


1997 CHAPTER 57
PAGE 3
Layer Sequence Wing

Figure 1, Sheet 1
PAGE DATE: 1.
15.June
December
1995 1999 CHAPTER 57
PAGE 4
Layer Sequence Wing

Figure 1, Sheet 2
PAGE DATE: 1.
15.June 1995 1999
December CHAPTER 57
PAGE 5
Layer Sequence Wing

Figure 1, Sheet 3
1. June
PAGE DATE: 15. 1995 1999
December CHAPTER 57
PAGE 6
57-05-01 Wing
Removal
Reverse procedure of installation omitting step 16.
Installation
1 Remove the canopy per Chapter 53, the engine cowl-

ings and the main fuselage cover per Chapter 51.
2 Remove the right front canopy hinge.
3 Loosen the breather line clamps located at the engine
side of the firewall and in the main spar area, push the
front part of the breather line some centimeters to the
front until it is disconnected from the connecting hose
(10, Figure 3) and remove the breather line (5) by pull-
ing it to the rear.
4 Fix throttle lever and control sticks in rearmost posi-
tion.
5 Remove RPM-vernier-control cable per Chapter 61 and
bring cable out of the main spar area.
CAUT I O N Ensure that areas in which the wing shall be slided are
clear of obstructions.
CAUT I O N Prevent cables and pitot/static lines for damage. Keep

them at the rear of the main spar and outside of the upper
longerons.
CAUT I O N Attend to the left front canopy hinge, the throttle and
mixer cables and the heater lever, when sliding down
the wing. These parts and the wing could be damaged.
WAR N I N G Beware not to get jammed between wing and fuselage.
6 Slide wing down into fuselage attachment brackets (3).
PAGE DATE:
DATE: 4.
1.June
June2009
1995 CHAPTER 57
PAGE 7
SERVICE MANUAL EXTRA 300L Wing
7 Install LN 9037-08042 auxiliary spar attach bolts (1)

from front to rear. Use two DIN 125-M8 washers and
LN 9348-08 nuts at each side for fastening.
I M PO R TAN T If there is clearance between the main spar and the at-
tachment brackets (1, Figure 2), use shims (3) like
shown below which are to be slided in the front gaps
(2).
Shims Installation
Figure 2
8 Slide in shims if necessary and install the main spar tu-

bular bolts (4, Figure 3) from front to rear.
9 Secure main spar tubular bolts with LN 9038-08020K
bolts (2), DIN912 M8 and aluminum 30x11x4 washers.
Torque security bolts for fastening and subsequently
safety wire.
10 Install upper longeron cutout bridges (7) using at each
side 3x DIN912 M8 x 180, 3x DIN125 M8 washers and
3x LN9348-08 stop nuts at the top and 1x DIN912 M10
x 230 bolt, DIN125 M10 washer and LN9348-10 stop
nut at the bottom (6). Check cutout bridges for RH and
LH marking. Install the bolts from front (firewall) to
rear (aircraft tail). Torque stop nuts for fastening.
11 Install the shear connectors (8). Use two DIN 912
M12x220 bolts and safety wire.

PAGE 8
12 Reinstall the front canopy hinge.

13 Reinstall RPM-Vernier-control and adjust.
14 Unfix throttle lever and control sticks.
15 Install short aileron push pull rods per Ch. 27-01-01.
16 Perform an aileron rigging per Chapter 27-11-02.
17 Connect fuel system (tubes and vent lines), pitot/static
system, stall warner, navigation/strobe light wires,
ground bonding leads and fuel indicator wires with
prefitted plugs per respective Chapters.
18 Reinstall breather line, canopy, engine cowlings and main
fuselage cover.

PAGE 9
Wing Removal/Installation
Figure 3

PAGE 10
57-35-01 Wing Tip Panel
Refer to Figure 1 of Chapter 33.

1 Disconnect the battery and wait 5 minutes.

2 Remove the DIN 933 M6x20 bolt, the metal sheet screws,
the AN 526 C 1032 R8 bolts and the washers.
3 Tie out the wing tip panel with the lighting unit some
centimetres (Consider that the panel is sealed to the wing
tip with silicone).
4 Disconnect the electrical wiring and the ground bonding
lead by loosening the central M4 nut of the lighting unit
attachment.
5 Remove the wing tip panel.
Silicone to the sealing surfaces.

PAGE 11
57-60-00 AILERONS
The ailerons are constructed in the same manner as the wing

but with single chamber spar. They are supported at three
points in spherical bearings pressed into aluminium brack-
ets. Furthermore the ailerons are equipped with "glass fibre
laminate spades" to decrease pilots forces.
The layer sequence of the ailerons is shown in Figure 4.
PAGE DATE: 1. June

June 1995
1997 CHAPTER 57
PAGE 12
EXTRA - FLUGZEUGBAU GmbH AILERONS
Note: Measurements are given in mm
Layer Sequence Ailerons

Figure 4

1997 CHAPTER 57
PAGE 13
EXTRA
Chapter 61
Propeller

PAGE 1
EXTRA
Table of Contents
Chapter Title
61-00-00 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
61-10-00 PROPELLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
61-20-00 CONTROLLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
61-20-01 Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
61-20-02 RPM Vernier Control Cable . . . . . . . . . . . . . . . . . . . . . 7

PAGE 2
EXTRA
61-00-00 GENERAL
The EXTRA 300L can be equipped with either a MTV-9-B-C/

C 200-15 (3-blade), MTV-14-B-C/C 190-17 (4-blade) or
MTV-9-B-C/C 198-25 (3-blade) propeller. Maintenance
work or overhaul of the propeller requires consultation of
the propeller manufacturer MT-Propeller.
Proper control,operation and maintenance of the propeller
is described in the Operation- and Installation Overhaul
Manual E-124 of the manufacturer.

PAGE 3
EXTRA
61-10-00 PROPELLER
The MTV-Propellers are made of laminated wood encased in

glass-fiber reinforced plastic, which is painted to make it
waterproof.
NOTE For more information about the propeller refer to MT-

Propeller Operation- and Installation Manual E-124.

PAGE 4
EXTRA
61-20-00 CONTROLLING
The pitch change is conducted by a propeller governor (refer

to Figure 1). Once an engine rotational speed is selected it
will be held constant at variations of airspeed and power.
The governor itself is actuated via a vernier control cable
ending on the left side of the rear cockpit. This cable is
routed on the left side of the fuselage, penetrates the firewall,
the rear air baffles and is then routed to the governor. The
cable is attached to the fuselage by a clamp block at its front
end and by self-clinching plastic straps in the cockpit area.
The clamp block serves also as a means for rigging. The fire
wall and air baffle penetration is covered with clamp sheets.
The firewall penetration is additionally sealed with PRC-
812 (Products Research & Chemical Corp., USA) firewall
sealant.
Mechanical stops for low pitch and high pich limit the pitch
change level. In case of the oil pressure of the govenor to be
lost, the blades automatically return to high pitch, if the
counterweights are installed. The oil pressure is single
acting.
Figure 1,
Controlling

PAGE 5
EXTRA
Figure 2,
RPM Vernier Control Cable Installation

PAGE 6
EXTRA
61-20-01 Governor
One of the following governors is installed:

MT-Propeller P-880-5, preset for a max. 2700 rpm
MT-Propeller P-880-41, preset for a max. 2600 rpm
Refer to the MT-Propeller Operation- and Installation Manual
E-1048 for further information.
NOTE The lever position of the governor actuator is preset.

Do not change this position.
61-20-02 RPM Vernier Control Cable
Removal
1 Ensure master switch is off.

2 Remove engine upper cowling per Chapter 71.
3 Remove main and bottom fuselage cover per Chapter
53.
4 Remove cotter pin, castle nut, washers and bolt from
the rod end (1, Figure 2) to governor actuator (2)
attachment.
5 Loosen counter nut and remove the rod end (1) from
the vernier control cable (6).
6 Remove rod end counter nut and vernier control cable
rubber parts (4).
7 Remove clamp block (5) attachment bolt.
8 Remove clamp block from the vernier control cable (6).
9 Remove clamp sheet attachment bolts on the rear air
baffle sheet and remove plastic grommets.
10 Remove clamp sheet attachment bolts on the firewall
and remove plastic grommets.
11 Mark vernier control cable routing and remove the self-
clinching plastic straps.

PAGE 7
EXTRA
12 Remove attachment nut (9) and washer of the vernier

control unit (7).
13 Pull the vernier control unit aft (about 15 cm) and then
inside the cockpit to remove.
14 Pull complete vernier control cable (6) aft to remove
from aircraft. Secure clamp sheets.
Installation
Install in reverse sequence of removal observing the following

items:
1 Thread the respective clamp sheets on the vernier
control cable before penetrating the firewall and the rear
air baffles.
2 Install rod end (1) with 8 rotations on the vernier control
cable (6). Ensure thread is visible in the inspection hole.
Apply inspection lacquer on the counter nut.
3 Renew the sealing of the bushing grooves and gaps at
the engine side of the firewall. Use PRC-812 (Products
Research & Chemical Corp., USA) firewall sealant.
5 Tighten the castle nut slightly. Ensure movability of lever.
Rigging
1 Bring vernier control knob (8, Figure 2) to the foremost

position.
2 Check that the travel stop is reached, and if the gap
between vernier control knob (8) and unit (7) is 5 mm
(tolerance +/-1 mm).
3 If not, loosen clamp block attachment bolt and adjust
the vernier control cable position in the clamp block
(5).
4 Fasten clamp block attachment bolt.
5 Check full travel.
6 If necessary adjust rod end (1) by the following steps:
a Remove cotter pin, castle nut, washers and bolt from
the rod end to governor actuator (2) attachment.

PAGE 8
EXTRA
b Loosen the counter nut and adjust rod end by turning.

Ensure thread is visible in the inspection hole when
fastening. Apply inspection lacquer on the counter nut.
c Reinstall the rod end to the governor actuator (2).

PAGE 9
EXTRA
Chapter 71
Power Plant

PAGE 1
EXTRA
Table of Contents
Chapter Title
71-10-00 COWLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
71-20-00 ENGINE MOUNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

71-20-01 Shock Mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
71-60-00 AIR BAFFLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

PAGE 2
EXTRA
71-10-00 COWLING
Description
The engine cowling is divided into two parts: The upper (1,
Figure 1) and lower (2) cowling made of GFRP or CFRP
honeycomb sandwich.
The upper cowling features a hinged hatch (3) for access to
the oil dip stick. This hatch is opened by two slotted head
flush type Camloc® retainers.
Both cowling parts are attached to each other and the airframe
by means of truss head screws (4) and special washers (5).
The interior surface of both cowling parts is coated with a
fire protection paint which is sealed by varnish coating.
Additional aluminized heat blankets are placed in the lower
cowling.
Figure 1;
Engine Cowling

PAGE 3
EXTRA
NOTE It is favourable to remove the cowling with two persons.
WARNING Before rotating the propeller in the most convenient

position for removal of the cowling, make sure that the
ignition switch is in the “OFF” position.
1 Rotate the 3 or 4 blade propeller in the most convenient

position.
2 Remove the related truss head screws (4)&(5) of the
upper cowling (see Figure 1).
3 Remove upper cowling.
4 Remove the remaining truss head screws (4)&(5) of the
lower cowling (see Figure 1).
5 Remove lower cowling.

PAGE 4
EXTRA
71-20-00 ENGINE MOUNT
Description
The engine is mounted on the airframe via the engine mount.

The engine mount is constructed of welded steel tubes and is
bolted to the firewall at 4 attachment points. The tubes of the
engine mount structure are provided with an internal anti
corrosion treatment. The engine mount itself carries the oil
cooler and is used as a support for various hoses of the oil
system as well as electrical wiring.
The engine is nested into the engine mount on a system of
rubber shock mounts, each of which comprises two rubber
elements and one tubular spacer (ref. Figure 2). The shock
mounts reduce the transmission of engine vibrations to the
airframe.

PAGE 5
EXTRA
Figure 2,
Engine Mount & Shock Mount Installation

PAGE 6
EXTRA
Removal
This paragraph describes the removal of the engine mount

from the engine (instructions in brackets for double oil
cooler system only!)
1 Disconnect (aft) oil cooler assembly (and separator)
from its supports at the engine mount by removing the
connection bolts and nuts, remove baffles if necessary.
2 Unscrew locknuts of the mounting bolts (refer to Detail
A on Figure 2) at the shock mounts.
3 Separate engine including oil cooler (and separator)
from engine mount. If necessary, push bolts outwards
for removal.
Installation
Install in reverse sequence of removal

Torque locknuts of connection bolts to engine shock mounts
with 55 Nm (40.5 ft. lbs.).
71-20-01 Shock Mounts
Description
The shock mounts serve as dampers to reduce the transmission

of vibrations induced by the engine to the aiframe.
The shock mounts consist of bonded rubber material with a
metal spacer at the center.
Each of the 4 shock mounts consists of two rubber halfs and
one tubular spacer (ref. Figure 1, Detail A) fixed by a single
bolt.

PAGE 7
EXTRA
Removal
CAUTION Replace the extracted shock mount before proceeding

with the removal of the next.
1 Support engine at its designated lifting lugs (ref.

Lycoming Maintenance Manual).
2 Unscrew locknut of the mounting bolt at one shock
mount (ref. Figure 1, Detail A).
3 Push bolt backwards to remove it.
4 Remove forward half of the shock mount.
5 Remove tubular spacer.
6 Extract aft half of the shock mount. If necessary, lower
respectively lift the engine a little to get the needed
clearance for removal of the aft shock mount half.
Installation
Install in reverse sequence of removal

Torque locknuts of connection bolts with 55 Nm (40.5 ft.
lbs.).

PAGE 8
EXTRA
71-60-00 AIR BAFFLES
Description
Refer to Figure 2. Air baffles are screwed to the engine to

achieve optimum engine cooling. These baffles are multi
section items designed for separate removal of each section.
They are manufactured of plated aluminium sheets. The
interface to the engine cowling is sealed by rubber stripes,
which are riveted to the outer edge of the baffles. Furthermore
the forward LH baffle has a circular cutout, serving as a
cooling air inlet that is connected with the exhaust’s heat
exchanger air intake via an air ducting.
Single oil cooler system:
The aft RH baffle has a rectangular cutout to provide airflow
to the oil cooler.
Dual oil cooler system:
The aft LH baffle has a circular inlet to provide airflow to the
aft oil cooler, which is connected to the baffle by an air
ducting.
In addition to the circular inlet described above, the forward
LH baffle has a rectangular cutout to support the forward oil
cooler.

PAGE 9
EXTRA
Figure 3,
Air Baffles
Removal
Refer to Figure 3 (Instructions in brackets for dual oil cooler

system only).
1 Disconnect bowden cable of RPM-control from engine
(refer to Chapter 61).
2 Disconnect fuel pressure sensing line at bulkhead of aft
RH baffle.
3 Disconnect ignition harness.

PAGE 10
EXTRA
4 Disconnect air ducting to exhaust heat exchanger at air

intake of forward LH baffle (to aft oil cooler at rear LH
baffle).
5 (Disconnect forward oil cooler assy at forward LH
baffle).
6 Unscrew grommets for ignition harness and RPM
bowden cable from their cutouts and pull out ignition
harness and RPM bowden cable.
7 Unscrew baffle plates.
Installation
Install in reverse sequence of removal.
NOTE Minor cracks in the plating can be stopped by drilling

a hole at the end of the crack. Serious damage requires
replacement of the baffle concerned.

PAGE 11
EXTRA
Chapter 72
Engine

PAGE 1
EXTRA
Table of Contents
Chapter Title
72-00-00 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
72-10-00 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

PAGE 2
EXTRA
72-00-00 GENERAL
This chapter describes the engine installed in the EXTRA

300L aircraft, together with its fitted assemblies. Operation
and maintenance work of the engine requires consultation of
the Lycoming Operator`s Manual (Refer to Chapter 01).
Proper control, operation and troubleshooting of the engine
is also described there.
Troubleshooting
1. Start by discussing the problem with the pilot and the

facility management people to assist you in narrowing
down the causes.
2. Review maintenance logs and use appropriate diagnostic
tools to eliminate simple and inexpensive solutions
before proceeding to more complicated and expensive
remedies. Often a quick visual inspection of the engine
will provide evidence of obvious problems, such as
intake and exhaust leaks, physical damage to ignition
harness, blocked breathers, gas and oil stains, etc.
3. Consult the following Troubleshooting Chart as a
diagnostic guide to the most common and recurring
problems, causes, and solutions. The chart provides this
information in a nonspecific format. Proceed from the
simplest possible cause to the most complex.

PAGE 3
EXTRA
Trouble Possible Cause Remedy

Engine will not start or is Defective battery Replace with a charged
hard to start battery per Ch. 24.
Rough idle Cracked engine mounts or Replace per Ch. 71.
defective shock mounts
Engine shock mount Install per Ch. 71.
improperly installed
Poor idle cutoff Improper rigging of mixture Adjust per Ch. 73.
control linkage
Engine will not turn static Restriction in induction air Inspect and remove
rpm or will not develop system restriction.
rated rpm.
Propeller is out of Adjust per Ch. 61.
adjustment (not reaching
specified low pitch).
Propeller governor is not Adjust per MT-Propeller
adjusted properly. Document E-1048.
Muffler’s internal baffles Strike muffler with a rubber
are broken and blocking the mallet or soft object and
exhaust outlet. Note: listen for a rattle. A rattle
Broken baffles are free to indicates loose baffles. Re-
move around in the muffler. move muffler for thorough
The engine may turn static inspection. Replace as
rpm’s intermittently. necessary per Ch. 78.
Throttle lever not properly Adjust per Ch. 73.
adjusted.
Engine surges Faulty governor Inspect and replace as
necessary per
MT-Propeller
Document E-1048.
Breather line plugged Inspect and remove any
obstructions from breather.
High oil temperature Insufficient cooling air Verify the integrity of the
air inlet and outlet ducting
to the oil cooler. Repair or
replace parts per Ch. 71.
Oil cooler lines are plugged Remove oil cooler lines
or partially plugged. and flush out per Ch. 79.

PAGE 4
EXTRA
72-10-00 ENGINE
The engine installed is a TEXTRON Lycoming 6-cylinder

direct drive, horizontally opposed, air cooled engine.
Engine type:
a) AEIO-540-L1B5 300 HP @ 2700 RPM
b) AEIO-540-L1B5D 300 HP @ 2700 RPM
c) AEIO-580-B1A 315 HP @ 2700 RPM
Figure 1 shows the Lycoming engine of the EXTRA 300L:
Lycoming engine
Figure 1
The induction system is equipped with a BENDIX RSA-10

fuel injection system which is attitude independent.
The fuel is injected into the intake ports of each cylinder. The
mixture control is proportional to the intake air flow. A
manual mixture adjustment as an overriding system is
provided. The power setting is done manually by means of a
butterfly valve in the air induction tube.
The engine is air cooled. Baffles are provided to build up a
pressure and force the air through the cylinder fins. The
cooling air flow is dependent on engine speed and dynamic
air pressure.

PAGE 5
EXTRA
The engine is lubricated by means of an engine driven oil

pump. The system uses an oil sump as reservoir. For acro-
batic maneuvers, lubrication is assured via an inverted flight
oil system (refer to CHRISTEN 801 Inverted Oil Sytem and
Chapter 79).
Oil temperature is limited by installation of 1 or 2 oil
coolers.
Ignition is a magneto type with 2 independent systems. A
Slick Start System is installed with the AEIO-580-B1A
engine.
NOTE For more information about the engine refer to

Lycoming Operator´s Manual.
I M PO R TAN T If replacement of the engine control cables is neces-

sealant. Cover the control cables with AEROQUIP
AE102-6 Fire sleeves inside the engine department.
Removal
NOTE In many cases it is favourable to remove the complete

engine incl. engine mount and all components of the
inverted oil system from the firewall; Then remove the
engine mount, the exhaust and engine accessories as
necessary.
After disconnection of lines and fittings, protect related

inlet by appropriate plug or cap. Cut self-clinching plastic
straps used for routing of lines and cables as appropriate.
This procedure is described in the following:
WARNING Before commencing any work, disconnect the battery

and short-circuit the magnetos with locking wire or
disconnect all ignition cables from the spark plugs.

PAGE 6
EXTRA
1 Remove the upper and lower part of the cowling (ref.

Chapter 71).
2 Support the engine at its two lifting lugs (ref. Lycoming
Maintenance Instructions).
3 Remove the canopy and main fuselage cover (ref.
Chapter 53).
4 Remove the LH & RH cuff from bottom fuselage cover
(ref. Chapter 53).
5 Remove the propeller spinner and propeller in
accordance with MT-Propeller Manual E-124, latest
revision.
6 Close fuel selector valve.
7 Disconnect the fuel supply hose at inlet of mechanical
(engine driven) pump.
8 Disconnect the drain tubing from mechanical fuel pump
housing.
9 Disconnect the oil valve unit of the inverted oil system
from the firewall.
10 Disconnect the crankcase vent hose at the fitting on top
of the oil separator of the inverted oil system (worm
drive hose clamp connection).
11 Disconnect the worm drive hose clamp of the engine
breather line at the firewall connection and remove the
oil separator of the inverted oil system from the engine
mount (for airplanes with two oil cooler system only).
12 Detach the rod end of Bowden cables for throttle and
mixture control at the control levers of the fuel control
servo. Disconnect Bowden cable attachment to the
engine.
13 Detach the rod end of Bowden cables for RPM control
at the control levers of the propeller governor.
Disconnect Bowden cable attachment to the engine and
related fairlead at the LH aft rear engine cooling baffle.
14 Disconnect the GND cable from the engine accessory
housing.
15 Remove the oil temperature sensor from engine oil
screen housing connection.

PAGE 7
EXTRA
16 Disconnect the exhaust gas and cylinder head tem-

perature sensors located at cylinder N° 5.
17 Disconnect the short-circuit and GND wire from engine
magnetos.
18 Disconnect the wire from retard connection of LH
magneto (for AEIO-580-B1A engine only).
19 Disconnect the wiring of the alternator and starter at
their electrical connection. Detach the fixation of the
wirings (which are covered with a firesleeve) to the oil
sump of the engine.
20 Disconnect the smoke oil supply hose at the smoke oil
injector nozzle on the exhaust end pipe (if a smoke
system is installed).
21 Disconnect the wet sense lines at the firewall connection
for engine manifold pressure, fuel pressure and oil
pressure.
22 Unbolt the complete engine with engine mount from the
airframe at the four attachments points.
23 Lift the complete engine from the airframe.
24 Refer to 71-20-00 for removal of the engine mount from
the engine.
Installation
1 Install in reverse sequence. Refer to Chapter 20-10-04

for torque values specified for the mount to the engine
and mount to the airframe connection.
2 Apply firewall sealant PR-812 (or equivalent) to the bolt
connection to the firewall/airframe. Follow the
applicable product instructions (mixing, application and
curing instructions).

PAGE 8
EXTRA
Chapter 73
Engine Fuel and Control

PAGE 1
EXTRA
Table of Contents
Chapter Title
73-20-00 CONTROLLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
73-20-10 Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
73-20-11 Throttle Control Cable . . . . . . . . . . . . . . . . . . . . . . . . . 4
73-20-12 Rear Throttle Control Lever . . . . . . . . . . . . . . . . . . . . . 6
73-20-12 Front Throttle Control Lever . . . . . . . . . . . . . . . . . . . . . 8
73-20-20 Mixture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
73-20-21 Mixture Vernier Control Cable . . . . . . . . . . . . . . . . . . . 9
73-30-00 INDICATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
73-30-10 Fuel Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
73-30-11 Fuel Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . 14
73-30-12 Sense Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
73-30-15 Engine Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

PAGE 2
EXTRA
73-20-00 CONTROLLING
73-20-10 Throttle
Refer to Figure 1. The throttle is controlled by means of the
throttle control levers located in the left side of the cockpit.
These levers are interconnected by the throttle control
linkage. The throttle control levers transfer their movements
to the throttle by means of the throttle control cable. This
cable is routed on the left side of the fuselage, penetrates the
firewall and is then routed centrally below the exhaust
muffler to the throttle. In the engine compartment this cable
is covered with a fire sleeve. The cable is attached to the
fuselage using clamp blocks at its ends, self-clinching plastic
straps in the cockpit area, and a cushioned clamp at the
exhaust muffler. The clamp blocks serve also as a means for
rigging. The fire wall penetration is sealed with PRC-812
(Products Research & Chemical Corp., USA) firewall sealant
and covered with clamp sheets.
Figure 1,
Throttle Control

PAGE 3
EXTRA
73-20-11 Throttle Control Cable
Removal

2 Remove engine cowling per Chapter 71.
the rod end (2, Figure 4) to throttle actuator (1)
attachment.
5 Loosen counter nut and remove the rod end from the
throttle control cable.
6 Remove rod end counter nut and throttle control cable
rubber parts.
8 Remove clamp block from the throttle control cable.
9 Remove cushioned clamp (4) and self-clinching plastic
straps in engine compartment.
10 Cut wires and remove fire sleeve from the throttle
control cable.
11 Remove clamp sheets from the firewall.
12 Mark throttle control cable routing and remove the
attachment self-clinching plastic straps in the cockpit
area.
13 Remove cotter pin, castle nut, washers and bolt and
remove the rod end (6, Figure 3) from the throttle
control lever (5).
14 Loosen counter nut and remove the rod end from the
throttle control cable.
15 Remove rod end counter nut and throttle control cable
rubber parts.
17 Remove clamp block from the throttle control cable (8).
18 Pull complete throttle control cable aft to remove from
aircraft. Secure clamp sheets.

PAGE 4
EXTRA
Installation

items:
1 Thread the respective clamp sheet on the throttle control
cable before penetrating the firewall.
2 Install both rod ends with 8 rotations to the throttle
control cable. Ensure thread is visible in the inspection
hole. Apply inspection lacquer on the counter nut.
3 Ensure distance between clamp sheet and clamp block
is 705 mm (refer to Figure 2).
Figure 2,
Firesleeve Length

Research & Chemical Corp., USA) firewall sealant. Let
the sealant slightly cure before thightening the clamp
sheet attachment bolts. This will strengthen the clamping.
5 Tighten the castle nuts slightly. Ensure movability of
levers.

PAGE 5
EXTRA
73-20-12 Rear Throttle Control Lever
Figure 3,
Throttle Control Levers
Removal

4 Remove cotter pin, castle nut, washers and bolt and
remove the control cable rod end (6, Figure 3) and the
throttle control linkage (3) from the throttle control
lever (5).
5 Pull the smoke switch out of the throttle lever handle.
6 Disconnect smoke switch wiring.
7 Remove intercom switch attachment nut.
8 Remove throttle control lever attachment bolt (7) and
remove throttle control lever. Thread the intercom
switch through the throttle control lever.

PAGE 6
EXTRA
Installation

items:
1 Thread the intercom switch and the smoke switch wiring
through the throttle control lever (5, Figure 3) before
positioning it.
2 Tighten the throttle control lever castle nut (7) slightly.
Ensure movability of levers (1 & 5).
Rigging
1 Bring throttle control lever (5, Figure 3) in a position

parallel to the adjoining fuselage structure steel tube.
2 Check the travel stop at the throttle is reached.
3 If not, loosen the attachment bolt of the front clamp
block (3, Figure 4) and adjust the vernier control cable
position in the clamp block.
Figure 4,
Throttle Control Cable Rigging
4 Fasten clamp block attachment bolt.

5 Check full travel. In the rearmost throttle control lever
position the residual travel shall be 8 mm.

PAGE 7
EXTRA

the rod end to throttle actuator (1) attachment.
b Loosen the counter nut and adjust rod end by turning.
c Reinstall the rod end to the throttle actuator (1).
73-20-12 Front Throttle Control Lever

4 Disconnect the throttle control linkage (3, Figure 3) from
the front throttle control lever (1).
5 Disconnect the throttle control handle (2) from the front
throttle control lever (1).
6 Remove front throttle control lever attachment bolt (9)
and remove throttle control lever.
7 Install in reverse sequence of removal. Tighten the
throttle control lever castle (9) nut slightly. Ensure
movability of levers.
73-20-20 Mixture
Refer to Figure 5. The mixture is controlled by means of the
mixture vernier control cable located on the left side of the
cockpit. This cable is routed on the left side of the fuselage,
penetrates the firewall and is then routed to the mixer. In the
engine compartment this cable is covered with a fire sleeve.
The cable is attached to the fuselage using a clamp block at
its front end and self-clinching plastic straps in the cockpit
area. The clamp block serves also as a means for rigging. The
fire wall penetration is sealed with PRC-812 (Products
Research & Chemical Corp., USA) firewall sealant and
covered with a clamp sheet.

PAGE 8
EXTRA
Figure 5,
Mixture Control
73-20-21 Mixture Vernier Control Cable
Removal

3 Remove main and bottom fuselage cover per Chapter
53.
the rod end (2, Figure 7) to mixer actuator attachment
(3).
5 Loosen counter nut and remove the rod end (2) from
the mixture control cable.
6 Remove rod end counter nut and mixture vernier control
cable rubber parts.
8 Remove clamp block (1) from the mixture vernier
control cable.

PAGE 9
EXTRA
9 Remove clamp sheet attachment bolts on the firewall

and remove plastic grommets.
11 Mark mixture vernier control cable routing and remove
the attachment self-clinching plastic straps.
12 Remove attachment nut and washer of the mixture
control unit.
13 Pull the vernier control unit aft (about 15 cm) and then
inside the cockpit to remove.
14 Pull complete mixture vernier control cable aft to
remove from aircraft. Secure clamp sheets.
Installation

items:
1 Thread the respective clamp sheet on the mixture control
cable before penetrating the firewall.
2 Install rod end with 8 rotations to the mixture vernier
control cable. Ensure thread is visible in the inspection
hole. Apply inspection lacquer on the counter nut.
Research & Chemical Corp., USA) firewall sealant.
5 Tighten the castle nut slightly. Ensure movability of
actuator 3, Figure 7).
Rigging
1 Bring mixture control knob to the foremost position.

2 Check that the travel stop is reached, and if the gap (see
Figure 6) between mixture control knob and unit is 5
mm (tolerance +/-1 mm).

PAGE 10
EXTRA
Figure 6,
Gap on Mixture Control Unit
3 If not, loosen clamp block (1, Figure 7) attachment bolt

and adjust the mixture vernier control cable position in
the clamp block.
4 Fasten clamp block (1) attachment bolt.
Figure 7,
Mixture Vernier Control Cable Rigging
5 Check full travel.

the rod (2) end to mixer actuator (3) attachment.

PAGE 11
EXTRA
b Loosen the counter nut and adjust rod end (2) by turning.
c Reinstall the rod end (2) to the mixture actuator (3).

PAGE 12
EXTRA
73-30-00 INDICATING
Fuel pressure is sensed on the EXTRA 300L engine and is

indicated to the pilot in command.
Trouble Shooting

No fuel pressure indication Gauge defective Replace gauge
Fuel pressure low Orifice in engine fuel
pressure fitting defective Clean fitting
Sense line leakage Replace sense line
73-30-10 Fuel Pressure
The fuel pressure gauge is located in the rear instrument

panel. The instrument takes fuel pressure from the wet line
(refer to Figure 8.) and because the fuel flow to the engine
cylinders is restricted, there is a direct relation between fuel
pressure and fuel flow.
Figure 8,
Fuel Pressure Wet Line

PAGE 13
EXTRA
73-30-11 Fuel Pressure Gauge
Refer to Chapter 31.
73-30-12 Sense Line

2 Remove clamps.
3 Disconnect the sense line from the fitting.
4 Remove the sense line.
5 Install in reverse sequence of removal. Torque sense line
fittings with 15.3 – 16.9Nm (135-150lbs-inch) and apply
inspection lacquer.
73-30-15 Engine Fitting
1 Remove cowling per Chapter 71

2 Disconnect the sense wet line.
3 Remove the fitting.

PAGE 14
EXTRA
Chapter 77
Engine Indicating

PAGE 1
EXTRA
TABLE OF CONTENTS
Chapter Title
77-00-00 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
77-10-00 POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
77-10-10 RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
77-10-11 Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
77-10-15 RPM Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
77-10-20 Manifold Pressure (MAP) . . . . . . . . . . . . . . . . . . . . . . . 5
77-10-21 Manifold Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . 5
77-20-22 Sense Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
77-20-00 TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
77-20-10 Cylinder Head Temperature (CHT) . . . . . . . . . . . . . . . . 7
77-20-11 Cylinder Head Temperature Gauge . . . . . . . . . . . . . . . . 7
77-20-15 CHT Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
77-20-20 Exhaust Gas Temperature (EGT) . . . . . . . . . . . . . . . . . . 8
77-20-21 Exhaust Gas Temperature Gauge . . . . . . . . . . . . . . . . . . 8
77-20-22 Sense Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
77-20-25 EGT Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

PAGE 2
EXTRA
77-00-00 GENERAL
The following engine instruments are installed in the EXTRA

300L:
1 tachometer
2 manifold pressure gauge
3 cylinder head temperature gauge
4 exhaust gas temperature gauge
Generally engine data is routed electrically from the engine
sensors (refer to Figure 1) to the instruments. However, the
manifold pressure line is routed through the firewall and
directly fitted to the instrument. The engine data are indicated
to the pilot in command.
Figure 1,
Engine Sensor Locations

PAGE 3
EXTRA
Trouble Shooting

No engine speed indication Tachometer defective Replace tachometer
No MAP indication Gauge defective Replace gauge
No MAP variation Sense line leakage Replace sense line
with power setting
No CHT indication Sensor or cable defective Replace sensor
Repair cable defect
CHT gauge defective Replace gauge
No or incorrect EGT Sensor defective Replace sensor with cable
indication Cable defective Replace cable with sensor
Gauge defective Replace gauge

PAGE 4
EXTRA
77-10-00 POWER
77-10-10 RPM
Engine speed data in the EXTRA 300L is obtained from the

magnetos. The tachometer is located in the rear instrument
panel and requires electrical supply bus voltage.
77-10-11 Tachometer
77-10-15 RPM Sensor
The RPM sensor is part of the engine, please refer to the

Engine Maintenance Manual.
77-10-20 Manifold Pressure (MAP)
The manifold pressure sense line is connected to the air inlet

of cylinder no. 5 (rear right-hand), refer to Figure 1. This line
is routed directly through the firewall to the indicator in the
rear instrument panel.
77-10-21 Manifold Pressure Gauge

PAGE 5
EXTRA
77-20-22 Sense Line

2 Remove clamps if applicable.
3 Disconnect the sense line from the fittings.
fittings with 15.3 to 16.9Nm (135 to 150 inch lbs.) and
apply inspection lacquer.

PAGE 6
EXTRA
77-20-00 TEMPERATURE
77-20-10 Cylinder Head Temperature (CHT)
The cylinder head temperature gauge is located in the rear

instrument panel. The sensor is located in the rear right-hand
cylinder (No. 5). For an installation with 2 oil coolers the
CHT sensor is located in the middle right-hand cylinder
(No. 3), refer to Figure 1.
77-20-11 Cylinder Head Temperature Gauge
77-20-15 CHT Sensor
The sensor is a bayonet type J thermocouple and is connected

directly with the overbraided wiring. This wiring cannot be
disconnected from the sensor and must not be shortened.

2 Identify CHT sensor using Figure 1.
3 Disconnect overbraided wires from electrical wiring.
4 Note correct wiring.
5 Remove sensor with complete overbraided wires from
engine.
6 Remove mounting fitting.
7 Install in reverse sequence of removal. Make sure wires
are connected correctly.

PAGE 7
EXTRA
77-20-20 Exhaust Gas Temperature (EGT)
The exhaust gas temperature gauge is located in the rear

instrument panel. The temperature sensor is located on the
rear exhaust pipe on the right-hand side (refer to Figure 1).
The sensor is mounted with a clamp. When leaning the
engine using EGT gauge, follow the procedures of the engine
manufacturer (Lycoming Service Instruction No. 1094).
77-20-21 Exhaust Gas Temperature Gauge
77-20-22 Sense Line

2 Remove clamps if applicable.
3 Disconnect the sense line from the fittings.
fittings with 15.3 to 16.9Nm (135 to 150 in. lbs.) and
apply inspection lacquer.
77-20-25 EGT Sensor
The sensor is a type K thermocouple and is connected

directly with the overbraided wiring. This wiring cannot be
disconnected from the sensor and must not be shortened.

PAGE 8
EXTRA
Removal

2 Identify EGT sensor using Figure 1.
3 Disconnect overbraided wires from electrical wiring.
4 Note correct wiring.
5 Loosen clamp and remove sensor with complete
overbraided wires from engine.
6 Install in reverse sequence of removal. Make sure wires
are connected correctly.

PAGE 9
EXTRA
Chapter 78
Exhaust

PAGE 1
EXTRA
Table of Contents
Chapter Title
78-00-00 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
78-10-00 COLLECTOR/NOZZLE . . . . . . . . . . . . . . . . . . . . . . . 4
78-10-01 Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
78-10-02 Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
78-10-03 Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
78-10-04 Heat Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

PAGE 2
EXTRA
78-00-00 GENERAL
The EXTRA 300L is generally equipped with a Gomolzig

6 in 1 exhaust system (refer to Figure 1) with integrated
silencer (muffler).
Figure 1,
Exhaust System

PAGE 3
EXTRA
78-10-00 COLLECTOR/NOZZLE
Description
Each engine cylinder has a separate exhaust pipe routed

down merging in collector tubes with increasing diameter.
The collector tubes are equipped with heat shields to protect
the lower engine cowling against the heat. Several exhaust
pipes feature slip joints to allow for thermal expansion.
The left and right collector tubes are merged further aft in the
muffler under the engine. An end pipe protrudes from the
muffler through the lower engine cowling for exhaust gas
discharge to the atmosphere.
Operation
The exhaust pipes are of welded stainless steel. These pipes

are routed from the cylinders down to the muffler under the
engine. The muffler comprises an inner pipe, which is
perforated, and an outer pipe to form a welded, sealed
structure.
The muffler is cooled using a surrounding heat shroud, which
is fed with fresh air from the forward LH baffle which is then
discharged to the athmosphere.
Trouble Shooting

Engine to loud Muffler defective Replace muffler per
Ch. 78-10-02.
Exhaust piping cracked Muffler not secured Reweld piping and tighten
clamps on muffler
Muffler too hot Check fresh air ducting
Cylinder outside sooted Gasket defective Replace gasket per
Ch. 78-10-03.
Exhaust flange bent Replace exhaust pipe per
Ch. 78-10-01.
Cowling inside damaged Heat shield defective Replace heat shield per
CH. 78.10-04.

PAGE 4
EXTRA
Removal
1 Remove upper and lower engine cowling per Ch. 71.

2 Remove EGT sensor on the right hand side rear cylinder
(No.5) per Chapter 77.
3 Remove throttle control cable at the injector, at the
attachment clamp block near the injector and at the
cushioned clamp on the muffler (refer to Chapter 73).
4 Remove the cooling air ducting on both forward and
rearward flanges on the muffler.
5 In case a smoke system is installed, remove the smoke
oil hose from the smoke oil injector nozzle on the
exhaust end pipe.
6 Loosen the nuts on the exhaust flanges and remove the
exhaust system.
Installation

items:
1 Use new gaskets.
2 Use new toothed lock washers.
3 Apply copper paste to the studs at the engine exhaust
openings.
4 Hold the exhaust system in place and tighten the nuts
(torque limit: minimal 4.5 Nm / 40 in.lb).
5 Be sure to correctly install the double ply flexible
ducting on the flanges (inner ply could obstruct flow).
Leakage Testing
This can be done without having to remove the system.

1 Loosen the screws that hold the heat shroud.
2 Inspect the muffler for cracks and corrosion.
3 Reweld minor cracks.
4 Replace parts which show major damage.

PAGE 5
EXTRA
78-10-01 Exhaust Pipe
Replacement
1 Remove exhaust system per Chapter 78-10-00.

2 For cylinders 1-2 replace entire collector tube.
3 For cylinders 3-4 pull the exhaust pipe out of the slip
joint and replace the exhaust pipe.
4 For cylinder 5 loosen the clamps on the slip joints,
replace the exhaust pipe and drill 4,8 mm (3/16") hole
for EGT sensor at identical location.
5 For cylinder 6 loosen the clamps on the slip joint and
replace the exhaust pipe.
6 Reinstall exhaust system in reverse sequence of re-
moval.
78-10-02 Muffler
Replacement
1 Remove exhaust system per Chapter 78-10-00

2 Loosen the clamps on the muffler side flanges and
remove the left and right collector tubes
3 Replace muffler and reinstall in reverse sequence of
removal
78-10-03 Gasket
Replacement
1 Remove exhaust system per Chapter 78-10-00.

2 Replace gaskets
3 Reinstall exhaust system in reverse sequence of removal

PAGE 6
EXTRA
78-10-04 Heat Shield
Replacement
Refer to Figure 2
2 Remove heat shield worm drive hose clips.
3 Replace heat shield.
4 Reinstall in reverse sequence of removal.
Figure 2,
Heat Shield Replacement

PAGE 7
Chapter 79
Oil System

PAGE 1
TABLE OF CONTENTS
Chapter Title
79-00-00 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
79-00-10 Christen Inverted Oil System . . . . . . . . . . . . . . . . . . . . . 3
79-00-11 Valve Balls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
79-20-00 DISTRIBUTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
79-20-02 Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
79-20-03 Flexible Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
79-20-10 Single Oil Cooler System . . . . . . . . . . . . . . . . . . . . . . . 8
79-20-20 Dual Oil Cooler System . . . . . . . . . . . . . . . . . . . . . . . . 9
79-30-00 INDICATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
79-30-10 Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
79-30-11 Oil Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
79-30-14 Oil Pressure Wet Line . . . . . . . . . . . . . . . . . . . . . . . . . 11
79-30-15 Engine Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
79-30-20 Oil Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
79-30-21 Oil Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . 12
79-30-25 Oil Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . 12

PAGE 2
79-00-00 GENERAL
79-00-10 Christen Inverted Oil System
The EXTRA 300L is equipped with a modification of a

Christen Inverted Oil System (CHRISTEN 801 series). The
need for modification of the standard Christen 801 Inverted
Oil System results from installation requirements of the
Lycoming engine. Maintenance work or overhaul of this
system requires consultation of the manufacturer. (Refer to
Christen Product Manual and Lycoming Operaton and
Installation Manual (refer to Chapter 01).
Description and Operation
The standard Christen 801 Inverted Oil System is a kit-form

accessory for Lycoming aircraft engines which permits
normal engine lubrication, with minimal oil loss, during
aerobatic flight. When installed, it becomes a self-contained
extension of the normal aircraft engine oil and breather
systems. As the system control valves are gravity-operated,
no connection to aircraft power sources is required (Refer
to Figure 1 and 2).
The system works in all inverted and negative-g flight
conditions and is particularly suited to high-performance
aircraft used for unlimited-class aerobatic competitions.

PAGE 3
INVERTED OIL SYSTEM
Normal flight
During normal flight, the weighted ball valve at the top of the
oil separator is open, allowing blow-by gases from the
engine crankcase to be vented from the breather port to the
top of the oil separator and out through the overboard
breather line. The top ball valve of the oil valve is closed and
the bottom ball valve is open, allowing oil to flow from the
sump fitting to the oil pump and out to the engine lubrication
points.
Inverted Oil System, Normal Flight

Figure 1
Inverted flight
When the aircraft is inverted, engine oil falls to the top of the
crankcase. the weighted ball valve in the oil seperator closes,
preventing overboard loss of oil though the top of the oil
separator. Blow-by gasses from the engine crankcase are
vented from the sump to the bottom of the oil separator and
out through the overboard breather line. The top ball valve of
the oil valve is open, and the bottom valve is closed, allowing
oil to flow out from the breather port to the oil valve, through
the sump fitting and the sump screen, to the oil pump and out
to the engine lubrication points.

PAGE 4
INVERTED OIL SYSTEM
SERVICE MANUAL EXTRA 300L Principles of Operation
Any oil in the lines which fails to return to the sump during
the transition between normal and inverted flight drains into
the oil separator. This oil then returns to the sump from the
bottom of the oil separator during periods of normal flight.
Inverted Oil System, Inverted Flight

Figure 2
Maintenance Practices
The inverted oil system normally requires no maintenance.

During major overhauls or when repairs require sump
removal, inspect sump for excessive deposits of sludge,
varnish, or foreign material. If sump is dirty, remove and
thoroughly clean all hoses and components; then use com-
pressed air blast for drying and cleanout before reassembly.
Cleaning
The inverted oil system must be flushed with a suitable

petroleum solvent, such as varsol, every 300 (three hundred)
hours of engine operation or when there is evidence of the
loss of oil through the breather line after normal flight.

PAGE 5
79-00-11 Valve Balls
Reseating
Marginal oil loss of valve may result from nicks in the valve
seats which cause leakage when the valve should be closed.
Such nicks can be caused by mishandling or by small chips of
metal being caught between the ball and the seat as the valve
operates during initial run-in of a new or overhauled engine.
For more information of the valves refer to Lycoming
Operaton and Installation Manual (see Chapter 01).

PAGE 6
79-20-00 DISTRIBUTION
The lubrication system of the EXTRA 300L features either

a single or dual oil cooler system both using flexible tubing.
The hose and fitting installation is modified with respect to
the standard Christen Inverted Oil System. The connections
of the Inverted Oil System however still consist of AN
(Army/Navy) Standard fittings.
The flexible tubing of the oil cooling system is connected
using AN Standard fittings with equal size (8D), but different
connection angles.
In operation the hot lubricating oil leaving the engine is
pumped by an engine-driven pump to a hose connector on the
engine mount which directs the oil to the oil cooler(s). The
oil is cooled in passing through the oil cooler(s) and returned
to the engine lubricating circuit through the return hose
tubing.
Maintenance Practices
Before making installations and repairs to the aircraft plum-

bing, it is important to make accurate identification of
plumbing materials.
79-20-02 Fittings
General information concerning fittings used in the EXTRA

300L can be found in Chapter 20-10-08.
79-20-03 Flexible Hoses
General information concerning flexible hoses can be found

in Chapter 20-10-07.

PAGE 7
I M PO R TAN T If replacement of oil lines is necessary, cover the oil

lines of the engine compartment with AEROQUIP
AE102 fire sleeves as per Chapter 20-10-07 except the
AEROQUIP 637/MIL-H 6000 hoses.
79-20-10 Single Oil Cooler System
When the single oil cooler system is installed the oil cooler
is located on the aft right hand engine side (see Figure 3).
Figure 3,
Single Oil Cooler System

PAGE 8
79-20-20 Dual Oil Cooler System
When the dual oil cooler system is installed the oil coolers
are mounted on the left front and left rear engine baffles and
are connected to the engine by flexible hose (refer to Fig. 4).
The two oil coolers are produced by the STEWART WARNER
SOUTH WIND Corporation.
Engine
Flexible Hose
Oil cooler Oil cooler
Figure 4,
Dual Oil Cooler System

PAGE 9
79-30-00 INDICATING
Oil pressure and oil temperature are sensed on the EXTRA

300L engine and are indicated to the pilot in command.
Trouble Shooting

No oil pressure indication Sensor defective Replace sensor.
Gauge defective Replace gauge.
Oil pressure low Engine oil pressure low Check engine oil pressure
with calibrated equipment.
Orifice engine fitting Clean fitting.
blocked
Sense line leakage Replace sense line.
Oil temperature high Sensor or cable defective Replace sensor.
Repair cable defect.
Gauge defective Replace gauge.
Incorrect engine oil Perform engine oil change.
79-30-10 Oil Pressure
The oil pressure gauge is located in the rear instrument

panel. The gauge receives its data electrically from a pressure
sensor located on the aft side of the firewall (refer to
Figure 5). The pressure sensor is connected to a bulkhead
fitting on the cold side of the firewall. A wet line connects the
bulkhead fitting to the reducer fitting at the engine.

PAGE 10
Figure 5,
Oil Pressure Sensor & Wet Line
79-30-11 Oil Pressure Gauge
Oil pressure indication is combined with the oil temperature

indication in one single unit.
79-30-14 Oil Pressure Wet Line
1 Remove upper cowling per Chapter 71

2 Disconnect the sense wet line at firewall bulkhead fitting
and at engine fitting (refer to Figure 5).

PAGE 11

fittings with 15.3 to 16.9Nm (135 to 150 in.lbs.) and apply
inspection lacquer.
79-30-15 Engine Fitting
1 Remove upper cowling per Chapter 71.

2 Disconnect the sense wet line per Chapter 79-30-14.
3 Remove the engine fitting.
4 Install in reverse sequence of removal. Torque engine
fitting with 15.3 to 16.9Nm (135 to 150 in.lbs.) and apply
inspection lacquer.
79-30-20 Oil Temperature
The oil temperature gauge is located in the rear instrument

panel. The gauge receives its data electrically from a sensor
located on the engine in front of the oil filter screen (refer
to Figure 6).
79-30-21 Oil Temperature Gauge
Oil temperature indication is combined with the oil pressure

indication in one unit.
79-30-25 Oil Temperature Sensor
The sensor can be easily removed and installed without

special equipment.
1 Remove upper cowling per Chapter 71.

PAGE 12
2 Remove oil temperature sensor (refer to Figure 6).

Figure 6
Oil temperature sensor location

PAGE 13
EXTRA
Chapter 91
Charts

PAGE 1
EXTRA
Table of Contents
Chapter Title
91-00-00 GENERAL ................................................................................................................ 3
91-10-00 ELECTRICAL WIRING DIAGRAMS .................................... 4

Wire Table .................................................................................................................... 4
System Reference Table ................................................................................... 5
Magneto System ..................................................................................................... 6
Navigation/Strobe Light System .............................................................. 7
Fuel and RPM-Gages ....................................................................................... 8
Radios .............................................................................................................................. 9
Audio Panel ............................................................................................................ 10
Low Voltage Warning System .................................................................. 11
Battery Circuit ..................................................................................................... 12
Alternator System ............................................................................................. 13
Fuel Boost Pump ............................................................................................... 14
Stall Warning System ..................................................................................... 15
Pedal Adjustment System .......................................................................... 16
Transponder ........................................................................................................... 17

PAGE 2
EXTRA
91-00-00 GENERAL
This chapter contains information about the electrical

wiring diagrams necessary to maintain the aircraft electri-
cal power sytem.

PAGE 3
EXTRA
91-10-00 ELECTRICAL WIRING DIAGRAMS
Wire Table
Figure 0

PAGE 4
EXTRA ELECTRICAL WIRING DIAGRAMS
System Reference Table

Figure 1

PAGE 5
Magneto System
Figure 2

PAGE 6
Navigation/Strobe Light System

Figure 3

PAGE 7
Fuel and RPM-Gages

Figure 4

PAGE 8
Radios
Figure 5

PAGE 9
Audio Panel
Figure 2

PAGE 10
Low Voltage Warning System

Figure 7

PAGE 11
Battery Circuit
Figure 9

PAGE 12
Alternator System
Figure 10

PAGE 13
Fuel Boost Pump

Figure 11

PAGE 14
Stall Warning System

Figure 12

PAGE 15
Pedal Adjustment System

Figure 13

PAGE 16
Transponder
Figure 14

PAGE 17
EXTRA
Chapter 95
Special Equipment

PAGE 1
EXTRA
TABLE OF CONTENTS
Existing Title
O GOMOLZIG EXHAUST SILENCER
O STEERABLE TAIL WHEEL
O ELECTRICAL ACTUATED RUDDER PEDAL

ADJUSTMENT
O ELT POINTER 3000
O AIR INDUCTION SCREEN
O P-1000 DIGITAL RPM INDICATOR
O CARBON SEATS
O EXTERNAL POWER SUPPLY
O HEATING SYSTEM
O CLEVELAND 40-151 WHEELS WITH

30-164 BRAKE ASSEMBLIES

PAGE 2

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SERVICE MANUAL

List of Effective Pages

List of Effective Pages

4 15. December 1999 22 16. January 2009 30 deleted

List of Effective Pages

24 1. June 1995 3 4. June 2009 5 4. June 2009

1. Ed. 1. June 1995 1. June 1995 Extra

List of Service Bulletins/Service Letters

SB-300-2-95 30.01.01 Upper Longeron Insp. 001 thr. 005 -

12, 14 thr. 20,

Securing the wire stirrup of the

001 thru 167, 1168*

Change Long Range Tanks- to 001 thr. 167, 1168*

List of Effective Pages ........................................................................................................................................................... A-C

Contents ................................................................................................................................................................................................ F-G

Group/Chapter title Chapter

General Description ...................................................................................................................................................................... 03

Standard Practices - Airframe ............................................................................................................................................... 20

Standard Practices and Structures - General ........................................................................................................... 51

Tel. N°: ........................................................... Fax N°: ..........................................................

To: EXTRA-Flugzeugproduktions- und Fax N°: ............................ (49)-2858-913730

Detailed Description of Damage or Problem

PAGE DATE: 16. June 2008

Tel. N°: ........................................................... Fax N°: ..........................................................

To: EXTRA-Flugzeugproduktions- und Fax N°: ............................ (49)-2858-913730

Existing Technical Documentation:

PAGE DATE: 16. June 2008 PAGE I

PAGE DATE:1. June 1995 CHAPTER 01

According to the regulations of the FAR part 23, this service

• Pilot´s Operating Handbook and Airplane Flight Manual

NOTE Check the following Airplane Log Book documents are

Carried in the airplane:

Engine: Lycoming AEIO-540-L1B5

• Operator´s Manual AEIO-540 (P/N:60297-21)

Propeller: MTV-9-B-C/C 200-15 (3-blade)

• Operation- and Installation Manual E-124

• Magneto Maintenance and Overhaul Manual

Manufacturer: UNISON INDUSTRIES

b) BENDIX Model No. D6LN-3000

Magneto Start Booster:

Cleveland Wheels & Brakes

Pointer 3000-10 ELT

• Operation and Installation Instructions

Artex ME406 ELT

• Descriptioon, Operation, Installation and Maintenance

Other Vendor Equipment

(Vendor publication should be obtained directly from the

01-00-01 Trade Marks

To keep the security risks during the execution of the

How to Use the Service Manual

PAGE DATE: 1. June 1995 CHAPTER 02

02-10-00 MANUAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . 3

PAGE DATE: 1. June 1995 CHAPTER 02

The set-up of the manual, the chapters and the handling

02-10-00 MANUAL DESCRIPTION

02-10-01 Manual Set-Up

The manual consists of groups, which are subdivided in

02-10-02 Chapter Set-Up

The chapter numbering system used in this manual repre-