Engine Overhaul Manual
Jabiru Aircraft
Pty Ltd
Jabiru 2200 & 3300 Aircraft Engines
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Dated : 28/10/2014
Issued By: AS
Page: 118 of 201
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7.5 Subassembly E
– Flywheel, Ignition Coils, Starter Motor And Alternator
7.5.1 Ignition Coils
Ignition coils are fitted with insulating washers between the coil and the mounting post. These are
essential as they greatly reduce the operating temperature of the coil, improving its longevity.
Ignition coils must be fitted with the output lead pointing in the direction of propeller rotation. Coils
installed backwards may fire with the wrong timing or not work at all.
Figure 144
– Ignition Coil Insulating Washer, Alternator Stator Thickness
7.5.2 Alternator
If a new alternator stator is being fitted it must be measured to ensure proper clearance (Figure 144,
right). Note that dome-head screws are used in the alternator magnet housing (Figure 145, right) are
used to allow clearance from the stator
– if normal socket head screws are used here alternator
damage will result.
Screw the alternator stator to the mount plate using machine screws. A small amount of Loctite 620 is
used on these screws.
7.5.3 Flywheel
If the engine is being updated to a “Starfish” style flywheel then the alternator rotor and the ignition
magnets must be fitted
– otherwise these parts are left undisturbed on the flywheel during overhaul.
Fit the ring gear to the flywheel using 6 off 1/4 x 1/2 Grade 8 bolts to the torque value given in Table 9.
Note the two tags fitted to the ring gear which are used by the tacho to measure RPM.
Whenever working with the rare-earth magnets used in Jabiru Engines, remember that shocks (like a
sharp tap with a hammer) and heat (such as from a heat gun when removing the flywheel screws) can
de-magnetise the magnets.
Each magnet retainer is fitted using 4 off 1/2" 10-32 countersunk screws. The magnets themselves are
potted in Silastic 1080 to prevent them vibrating. Note that the magnets must be set with their north
poles facing outwards. After assembly the magnet assemblies must be tested as detailed in Section
Table 13. If necessary new magnets may need to be fitted.
The alternator rotor assembly is located on the flywheel using 4 roll pins. These are fitted to the
flywheel, then the rotor tapped into place using a soft hammer. The rotor is then screwed to the
flywheel using 4 off 5/8” x 10-24 button head cap screws. A small amount of Loctite 620 is applied to
these screws.
Finally the “starfish” adaptor itself is screwed to the flywheel using 8 off 1/4" x 5/8" UNF cap screws &
Belleville washers (torque per Table 9)
. Loctite 620 is applied to these screws. Note that the “starfish”
Insulating washer between coil and mount
