Section 31, Motor Assembly, SeaRey, LSA

Progressive Aerodyne, Inc.

3801 State Rd 19
Tavares, FL 32778

Revision Description Remarks Date

03 Update Pg 25, added a machine screw to block overflow ports 01/21/2013
04 Update Pg 22, changed the size of the oil hose to ½” 02/28/2013
05 Update Page 11, changed to new part # for Fuel Sump Shut-Off Bracket 04/02/2013
06 Update Page 21, clarify Oil Cooler mounting 10/03/2013
07 Update Page 34, figure 32.4, changed design of static port 10/28/2013
08 Update Pgs 26 & 27, Clarify assembly of the radiator for 912 03/11/2014
09 Update Pg 22, change bolt size on step 19.1 to a AN4-07A 04/10/2014
10 Update Pg 27, edited dimensions for root tube radiator holes 09/12/2014

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1.0 Scope
This document will detail the steps necessary for final assembly of the Engine Related Components.

2.0 Applicable Documents

N/A

3.0 Requirements
3.1 Equipment
3.1.1 The following tools will be necessary to perform this procedure:
 Awl or Adjustable Wrench
 Drill Bits, Jobber Length, 3/16”
 Drill, Electric, or Cordless
 Hammer, Plastic Tip
 Marker
 Open End Wrench, 3/8”
 Open End Wrench, 7/16”
 Open End Wrench, 1/2”
 Socket Set, SAE, 3/8” and 7/16” sockets

3.2 Materials
The following general supplies will be necessary to perform this procedure:

 Lacquer thinner (Cleaning labels off of parts)

 Protective gloves

3.3 Procedure (See the following pages)

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 Section 31, Motor Assembly, SeaRey, LSA

Carburetor Inlet/Outlet tubes

Kit Carburetor

Inlet/Outlet tubes

Heater Block

Remove Carb

Figure 1. Installing Carburetor Heat

Note: Refer to Skydrive 912 Coolant Carburetter Heater – MKIII directions

1.1 Open up the Carburetor Heater for 912S (7240-034) Kit and lay out the parts.
1.2 Remove the carburetor from the motor at the Intake Manifold.
1.3 Fit the Heater Block to the carburetor with the inlet/outlet tubes facing up and aft. Smear a thin film of Loctite 648 onto the rim of the carburetor
throat. Tap the Heater Block on with a plastic mallet keeping it square. Now squeeze in with a vice.
1.4 Hold Carburetor upright and squeeze 10 drops of Loctite 648 down the threaded hole on top of the heater block. Screw the screw fully home
using a 2.5mm allen key. Lay the carburetor in a warm place, on its side with the throttle lever uppermost so any seeping Loctite wil run away
from the spindle. Let Loctite cure for a couple of hours. Clean any seepage into the carb bore.
1.5 Re-Install the carburetor to the manifold and tighten the clamp. Re-connect fuel feed pipe.

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 Section 31, Motor Assembly, SeaRey, LSA

Inlet/Outlet tubes

Small “T”

Figure 2. Installing Carburetor Heat Hoses

Note: Refer to Skydrive 912 Coolant Carburetter Heater – MKIII directions

2.1 Cut the heater hose between cylinder #2 and the expansion tank and install the Smaller “T” connector. Use the hose clamps supplied to
secure the hose.
2.2 Install the end of the small hose supplied and fit onto the “T” connector with a clamp.
2.3 Cut the hose just before the water pump inlet and install the Larger “T” connector. Use the hose clamps supplied to secure the hose.

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 Section 31, Motor Assembly, SeaRey, LSA

Inner connector Inner connector

Outer connector

Figure 3. Installing Carburetor Heat Hoses

Note: Refer to Skydrive 912 Coolant Carburetter Heater – MKIII directions

3.1 Install a piece of rubber hose between the two inner connectors of the heater blocks on both carburetors. Secure with the hose clamps
supplied.
3.2 Fit a length of hose to the outer heater block connector (cylinder 1 & 3 carb) and return to the Larger “T” connector. Secure with the hose
clamps supplied.
3.3 Take the hose from Smaller “T” connector and attach it to the outer heater block connector (cylinder 2 & 4 carb). Secure with the hose
clamps supplied.

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 Section 31, Motor Assembly, SeaRey, LSA

Air Filter Air Filter

Hole for
Safety Wire

Figure 4. Installing Air Filters onto Carburetors

4.1 Slightly coat the surface of the Air Filter, Rotax 912/912S (#7210-001) with K&N filter oil supplied. Slide the mouth of the filter over the
throat of the carburetor. Secure with the hose clamp supplied.
4.2 Puncture a hole through the rubber end of the filter base and safety wire the filter back to the carburetor.

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 Section 31, Motor Assembly, SeaRey, LSA

Hose Clamp

Fuel Filler
Hose

Fuel Filler
Cap

Figure 5. Installing Fuel Filler Hose and Fuel Filler Cap

5.1 Take the Hose, 1-1/2” Pre-Formed Fuel Filler (2810-018) and slide the longer end of the “S” over the Fuel Filler Barb in the left side of the
fuel tank. Mark where the other end of the fuel hose comes out against the Turtle Deck. Approximately 23” back from Turtle Deck front
edge and 6” up the Turtle Deck/Hull seam. Install a Hose Clamp #24 (#7310-009) on the Fuel Tank end.
5.2 Use a 2” hole saw and cut a hole in the side of the Turtle Deck. Use a hot knife to trim the carpet away. File the edges of the fiberglass.

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 Section 31, Motor Assembly, SeaRey, LSA

Fuel Filler
Hose Clamp Cap

Screw #10- Screw #10-

32 x ¾” 32 x ¾”

Fuel Filler
Hose

Fuel Filler
Cap

Figure 6. Installing Fuel Filler Hose and Fuel Filler Cap

6.1 Test fit the Fuel Filler Cap (2810-003). Put a bead of caulk on the back side of the filler cap flange and insert into the hole with the filler oriented
properly.
6.2 Drill (3) 3/16” holes through the screw holes in the fuel filler into the fiberglass Turtle Deck. Be careful not to catch the carpet. Burn holes in
carpet with a hot knife.
6.3 Install (3) Screw #10-32 x 3/4” Dome Head (S75-1032) through the Fuel Filler Cap, Turtledeck Hull, Washer AN3, Nut AN3 Lock, and tighten.
6.4 Install Hose Clamp #24 (7310-009) onto the fuel filler cap end of the fuel hose, connect to fuel filler and tighten.

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 Section 31, Motor Assembly, SeaRey, LSA

Hose Clamp Fuel Tank

Vent

Hose

Fuel Tank
Vent

Figure 7. Installing Fuel Tank Vent

7.1 Locate area to install the Fuel Tank Vent (7310-005): Mark center at 27” aft of Turtle Deck front edge and 6” up from the Turtle Deck/Hull seam.
Cut a 3/4” hole in the Turtle Deck. Trim Carpet. File edges.
7.2 Slide the Fuel Tank Vent (7310-005) in from the front side with the vent facing down. Apply a bead of caulk on the backside flange. Install
retaining nut from the back side and tighten.
7.3 Install the Hose, 5/8 I.D. Clear per ft (3’) (2820-002) onto the Vent Barb on the fuel tank. Slide on Hose Clamp #06 (#7310-022) and secure to
Vent Barb. Slide on Hose Clamp over hose. Slide on the hose to the Fuel Tank Vent. Set Hose Clamp #06 (#7310-022) into position on barb and
tighten.

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 Section 31, Motor Assembly, SeaRey, LSA

Aluminum
Nut

Bulkhead
Hose Elbow

Figure 8. Installing the Fuel Sump Elbow

8.1 Install the Elbow, Hose Bulkhead 90 Degree (2910-030) into the side of the Hull. 7” back from centerline of Upper Bulkhead Cross Tube and 2-
3/4” down from Turtle Deck to Hull seam. Drill a ½” hole for the Elbow and insert through the hull. Install an Aluminum Nut (2910-031) on the
inside over the threads of the Elbow.

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 Section 31, Motor Assembly, SeaRey, LSA

Rivet
SBL44
Nut

Fuel Flow
Valve
Fuel Sump Valve
Mount Bracket

Figure 9. Installing Fuel Sump Shut Off Valve

9.1 Install Fuel Sump Shut-off Bracket (2810-030) to the forward fuel tank angle support. Measure in 5” from side of Turtle Deck to centerline
of bracket. Using the (2) 1/8” holes in the center of the bracket. Drill through the bracket and into the forward fuel tank angle support.
9.2 Rivet bracket in place with Rivet SBL44 (SL-44).
9.3 Install the Fuel Flow Valve (7310-035) to the bracket. Use the supplied retainer nut and attach the fuel flow valve with the inlet side
coming from the inboard side, the return side facing down and the lever to the outboard side.

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 Section 31, Motor Assembly, SeaRey, LSA

Fuel Flow
Valve

Sump Line Primer

to Primer Extend Bulb Extend down
Bulb down to to Bulkhead
Fuel Tank Hose Elbow

Figure 10. Installing Fuel Sump Shut Off Valve hoses

10.1 Slide a Hose Clamp #02 (#7310-007) onto Fuel Hose, 1/4” Dia. (#7310-004) and push the fuel line onto the 1/4” barb sump fitting on the
bottom of the fuel tank (bottom of 2 fittings).
10.2 Install the Primer Bulb, 1/4” Barb (7320-002), Center between the tank and the fuel shut-off valve. Cut lengths of hose to fit and install
Hose Clamp #02 (#7310-007).
10.3 Install a piece of Fuel Hose, 1/4” Dia. (#7310-004) from the fuel shut-off valve to the Bulkhead Hose Elbow in the side of the Hull. Put on
Hose Clamp #02 (#7310-007) and tighten.

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 Section 31, Motor Assembly, SeaRey, LSA

Return Fuel Return Extend

Line Fuel Line down to
Fuel Tank

Figure 11. Installing the Fuel Return hoses

11.1 Connect Fuel Hose, 1/4” Dia. (#7310-004) with Hose Clamp #02 (#7310-007) to the return 1/4” barb fitting on the fuel tank. (top tank fitting, aft of
3) Run the line around the arch, through the pylon chase, down the Root Tube to the top of the motor (return fuel connection). Adjust length to fit
and connect to return line fitting 1/4” on the motor with a Hose Clamp #02 (#7310-007).

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 Section 31, Motor Assembly, SeaRey, LSA

AN6 Barb
Fuel Line to Connector
Motor

Forward

In
Out

Fuel Pump

Figure 12. Installing Fuel Hose from Motor to Fuel Pump

12.1 Connect fuel inlet hose on motor to Fuel Hose, 3/8” Dia. (#7310-048). Use Brass Fitting 3/8” Barb x 3/8” MJIC Push-on Fitting (#7240-026) to
connect raw 3/8” fuel hose to the engine inlet fuel hose. Install Brass Fitting into the female end of the motor fuel hose. Push 3/8” Fuel Hose
onto the barb.
12.2 Run the Fuel Hose, 3/8” Dia. (#7310-048) down the Root Tube Forward and down into the Pylon to the fuel tank area.
12.3 Bring the Fuel Hose, 3/8” Dia. (#7310-048) to the outlet side of the Facet Fuel Pump 40105 (#1510-246).
12.4 Install the 1/8” NPT x 3/8 Barb Fitting (#7310-044) to the inlet and outlet end of the fuel pump.
12.5 Push the Fuel Hose, 3/8” Dia. (#7310-048) onto the outlet barb on the fuel pump. Install Hose Clamp and tighten.
12.6 Push length of Fuel Hose, 3/8” Dia. (#7310-048) onto the inlet barb on the fuel pump. Install Hose Clamp #02 (#7310-007) and tighten. Route
hose down to Fuel Tank bottom front of Tank.

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 Section 31, Motor Assembly, SeaRey, LSA

Forward
Fuel Pump

Fuel
Fuel Line to Filter
Tank
In

Fuel Pump

Figure 13. Installing Fuel Line from Fuel Pump to Tank

13.1 Half way down to the fuel tank behind bulkhead, install Fuel Filter, Aeromotive 12316 In-Line (#7310-060). Install Hose Clamp #02 (#7310-
007) on outlet end. Install Fuel Hose, 3/8” Dia. (#7310-048) on inlet end and install Hose Clamp #02 (#7310-007).
13.2 Run the Fuel Hose, 3/8” Dia. (#7310-048)from the Fuel Filter down to the upper fuel fitting (3/8”) on the bottom front of the fuel tank. Slide
Hose Clamp #02 (#7310-007) on the Hose and push the Hose onto the 3/8” fuel tank barb. Tighten.

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 Section 31, Motor Assembly, SeaRey, LSA

Mini Shutoff Fuel Hose Forward

Valve back to
Motor

Fuel Line
back from
Shutoff Valve

Valve in closed
position

Figure 14. Installing the Fuel Shut Off Valve

14.1 Install a Hose Barb, 3/8” x 3/8” (#7310-021) into the inlet and outlet end of the Mini Shutoff Valve (7310-043). Wrap the threads with tephlon
tape prior to installing.
14.2 Behind the Turtle Deck arch install the Mini Shutoff Valve (7310-043). Mount the Fuel Shutoff Valve Mount Bracket (7310-042) by drilling
1/8” holes in the Turtle Deck arch that line up with the holes in the Bracket.
14.3 Install (2) Rivet SLB44 (SL-44) into Bracket into arch.
14.4 Cut the Fuel Hose, 3/8” Dia. (#7310-048) behind arch. Install a Hose Clamp #02 (#7310-007) on each end of the Hose.
14.5 Push the inlet and outlet Fuel Hose onto the Fuel Shutoff Valve. Position Hose Clamps and tighten. Zip Tie hoses secure.

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 Section 31, Motor Assembly, SeaRey, LSA

Oil Tank
Mount

Rivet SB6-8 Oil Tank

Mount

Figure 15. Installing Oil Tank Bracket to the Root Tube

15.1 Locate position for the Oil Tank Mount (7530-004) on the Root Tube: Go back 52-1/2” from the forward end of the Root Tube to the center of the
Oil Tank Mount.
15.2 Drill (6) 3/16” holes through the pre-drilled holes in the Oil Tank Mount into the Root Tube.
15.3 Install (6) Rivet SB6-8 (SP-66).

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 Section 31, Motor Assembly, SeaRey, LSA

Hose Oil Tank

Clamp Mount
#96

Hose
Clamp
#40

Coolant
Recovery
Bottle
Mount

Coolant
Recovery
Bottle

Figure 16. Installing Oil Tank & Coolant Reservoir Recovery Bottle

16.1 Place the (2) Hose Clamp #96 (7310-010) over the Oil Tank Mount (7530-004). Slide the oil tank inside the Hose Clamp #96.
16.2 Now position the Coolant Recovery Bottle Mount (7510-011) inside the two Hose Clamps #96 at the aft right side. (Leave loose.)
16.3 Place the two Hose Clamp #40 (7310-029) around the recessed bend in the Coolant Recovery Bottle Mount.
16.4 Slide the Coolant Recovery Bottle (7510-010) inside the Hose Clamp #40. Leave loose.
16.5 Tighten the Hose Clamp #96 around the Oil Tank and space the drain plug on bottom 1/4” above the bracket.
16.6 Now tighten the Hose Clamp #40 around the Coolant Recovery Bottle, centering in best position.

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 Section 31, Motor Assembly, SeaRey, LSA

Coolant
Hose

Coolant
Hose

Coolant
Recovery
Bottle Coolant
Reservoir

Figure 17. Installing Coolant Reservoir Recovery Bottle Hose

17.1 Push the Hose, ¼ I.D. x 3/8 Vinyl (#7510-021)(coolant overflow tube) inside the Coolant Recovery Bottle and route back to coolant reservoir fitting.
Cut coolant hose to proper length.
17.2 Slide on a Hose Clamp #02 (7310-007) on clear coolant hose at the coolant reservoir end. Push coolant hose onto the nipple of the coolant
reservoir. Position the Hose Clamp and tighten.

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 Section 31, Motor Assembly, SeaRey, LSA

Oil Tank Oil Tank

Fittings (In) Fittings (out)

Oil Tank
Fittings (out)

Figure 18. Installing Oil Tank Fittings

18.1 Install Oil Tank Fittings (7240-030) onto the inlet and outlet of the oil tank.

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 Section 31, Motor Assembly, SeaRey, LSA

Oil Cooler
Support Strap

Bolt AN4-07A

Bolt AN4-06A

Oil Tank
Fittings (out)

Engine Angle

Oil Cooler, Oil Cooler,

Oil Cooler 12 Plate
Mounting Angle 12 Plate
Bolt AN4-05A

Figure 19. Installing Oil Cooler

19.1 Mount Oil Cooler Mounting Angle (7520-013) to the Engine Angle, 3 x 4 x 14 L & R (#7220-019 & 021). Center up the Oil Cooler Mounting Angle
on the back of the Engine Angle. Mark hole location from Mount Angle onto the Engine angle. Drill ¼” holes in the Engine Angle. Install the Engine
Angle to the Mount Angle with Bolt AN4-07A, Washer, AN4, Mounting Angle, Engine Angle, Washer, AN4 and Nut AN4.
19.2 At the bottom of the Oil Cooler (7240-036) attach the Oil Cooler Support Strap (7520-014) with Bolt AN4-05A (AN405A).
19.3 Attach the Oil Cooler to the Oil Cooler Mounting Angle with Bolt AN4-06A, Washer AN4, Oil Cooler Mounting Angle, Oil Cooler Support Strap, Oil
Cooler, Washer AN4 and Nut AN4 and tighten.
19.4 Install Pipe Fitting FCM2008-08AN to 1/2" NPT (7310-045) into the Oil Cooler on inlet and outlet ports. Install Oil Tank Fitting (7240-030)
onto the Fittings.

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 Section 31, Motor Assembly, SeaRey, LSA

Step 20.1 Step 20.4

Step 20.2
Step 20.7

Oil Tank Co-Pilot

Oil Hose bottom Fitting Side Fitting
of Motor

Figure 20. Installing Oil Lines

20.1 Install previously installed Oil Hose, ½” ID (#7310-023) that was connected to the oil return on the bottom of the motor. Connect hose to the
Oil Tank Fittings (7240-030). Cut hose to proper length to reach Oil Cooler pilot side. Slide Hose Clamp #06 (7310-022) on 1/2” hose. Push
hose onto fitting and tighten Hose Clamp.
20.2 Install Oil Tank Fitting (7240-030) onto the back of motor.
20.3 Slide a Hose Clamp #06 (7310-022) onto the Oil Hose, ½” ID (#7310-023). Push hose onto the Oil Tank Fitting (7240-030) and tighten.
20.4 Run oil hose down to the oil cooler co-pilot side fitting.
20.5 Cut Oil Hose, ½” ID (#7310-023) to proper length and push onto the Oil Tank Fitting with a Hose Clamp #06 (7310-022). Adjust Clamp and
tighten.
20.6 Install hose onto the oil tank out Fitting. Push 1/2” hose and clamp and tighten.
20.7 Run hose down to the oil cooler pilot side fitting.
20.8 Oil cooler adapter and oil tank fitting into top ports of oil cooler previously installed.
20.9 Cut Oil Hose, ½” ID (#7310-023) to proper length. Install Hose Clamp #06 (7310-022). Slide on hose to oil tank fitting and tighten clamp.

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 Section 31, Motor Assembly, SeaRey, LSA

Muffler

Exhaust Pipe
Exhaust Port

Figure 21. Installing Muffler

21.1 Remove the factory exhaust ports from the engine heads at (4) locations.
21.2 Install CKT SS Exhaust System (#7820-013). Install the (4) exhaust pipes onto the engine heads and put the (2) nuts on each pip loosely. (See
pictures for locations.)
21.3 Place the muffler on top of the motor and start to install the pipes into the ports on each side of the muffler. Locate the exhaust port on the
pilot side.
21.4 Start working your way around to each nut and tightening in slow intervals until they seat properly, and fully tighten.

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 Section 31, Motor Assembly, SeaRey, LSA

Muffler

Retention Spring Silicone Caulk Safety Wire

Figure 22. Installing Muffler Retention Springs

22.1 Install muffler retention springs. One spring for each pipe will connect on a welded ring on the pipe to a single loop welded to the muffler.
22.2 Loosen up the Allen head bolt on the co-pilot side forward pipe just to set final location, and then re-tighten.
22.3 Run a bead of silicone caulk along each spring coil length and then safety wire each spring.
22.4 Run a safety wire through the loops on the muffler and exhaust pipe, through spring. Leave 1/4” play – not snug tight.

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Radiator

Radiator

Radiator Cowl

Spacers (4) Bolt AN4-12A

Figure 23. Assembling the Radiator

23.1 Prior to installing the Radiator (#7510-001). Remove the two mounting tangs on the bottom and top tank on the water inlet and outlet side.
23.2 On the Radiator at the opposite end of the inlet and outlet tank install the Radiator Plug with Gasket (#7510-007). Use tephlon tape.
23.2 Install Radiator (#7510-001). On the topside of both ends of the radiator tanks there is an overflow tube. Both of these will need to be
plugged. Tap the mount holes with a 1/4-28 tap bit. Use a Screw, #10-32 x ¾, Dome Head (#S75-1032) wrapped with Teflon tape and insert
into each of the tubes.
23.3 On the top side of the rear end of the radiator tank there are two mounting holes. Using the pilot side hole, drill 3/16” completely through into
the tank. Tap hole with 1/4-28 tap bit.
23.4 Set the radiator into the Radiator Cowl, Fiberglass (#7510-002) with the water inlet and outlet protruding through the Cowl. Drill a ¼” hole
through the fiberglass Cowl at the side mounting points for the radiator.
23.5 Insert Bolt AN4-12A with Washer, ¼ x 1” SS Fender (#FW100-14) through cowl, (4) Plastic Spacer, 1/8”, Radiator, Washer, AN4 (#N4W), Nut,
AN4 Lock (#N4LN) and tighten.

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Bolt AN4-05A Radiator Cowl

Rivet
Rubber Filler

Radiator Pan Bolt AN4-23A

Bolt AN4-23A

Figure 24. Mounting the Radiator to the Pan

24.1 On the top side of the rear end of the radiator tank there are two mounting holes. Using the pilot side hole, drill 3/16” completely through into the
tank. Tap hole with 1/4-28 tap bit.
24.2 The above hole is for a vent to purge system. Install an Allen Bolt 1/4-28 and tighten.
24.3 Bring the Radiator assembly over to the plane Root Tube. Locate the 1/4” holes in the Root Tube, 32-1/4” and 47-7/8” from forward end of Root
Tube.
24.4 Mount the Radiator Bracket, Aft (7530-002) and Radiator Bracket, Forward (7530-008) to the Root Tube using Bolt AN4-23A with Washer, AN4
(#N4W) through the Radiator Bracket, Root Tube, Radiator Bracket, Washer, AN4 (#N4W), Nut, AN4 Lock (#N4LN) and tighten.
24.5 Position the Radiator Pan (#7530-003) onto the on the Radiator Bracket, Aft (7530-002) and Radiator Bracket, Forward (7530-008) with the aft of
the pan flush with the AFT Bracket. Mark the holes from the Radiator Brackets onto the Radiator Pan and drill out to ¼” holes.
24.6 Install the Radiator Pan (#7530-003) to the Radiator Cowl, Fiberglass (#7510-002). Drill (9) 1/8” holes into the bottom edge of the Radiator Cowl
into the Radiator Pan turned up edge. Install Rivet SBL44 (SL-44) to secure the Radiator Cowl to the Radiator Pan.
24.7 Place the Radiator Pan on top of the Radiator Brackets and attach using Bolt AN4-05A with Washer, AN4 (#N4W), Radiator Pan, Radiator
Bracket, Washer, AN4 (#N4W), Nut, AN4 Lock (#N4LN) and tighten.
24.8 Install a strip of Rubber Filler, ¾ x 3/8 (#5510-011) on each outside edge of the Radiator Pan (#7530-003) on the bottom.

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 Section 31, Motor Assembly, SeaRey, LSA

Radiator to
Water Pump
Radiator to Engine

Figure 25. Installing Radiator Hoses to the Motor

25.1 Install radiator hoses: On co-pilot side use Radiator to Engine Hose (7510-019) – slip on Hose Clamp #16 (7310-008 ) and slip hose onto
motor header tank and then connect other end to Radiator.
25.2 Install radiator hose pilot side use Radiator to Water Pump Hose (7510-020). Install Hose Clamp #16 (7310-008 ) over hose and connect
hose to the water pump outlet – connect other end to radiator pilot side. Tighten clamps.
25.3 Cut radiator hose at middle and install Radiator Hose Connector Tube, 1” Aluminum (#7510-033). Install Hose Clamp #16 (7310-008 ) on both
sides. Repeat to other side (pilot side) with Carb Heat “T” Fitting.

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 Section 31, Motor Assembly, SeaRey, LSA

Zip Tie
Bolt AN3-15A Cables
Throttle Cables

Figure 26. Installing Throttle Cables

26.1 Connect Throttle Cable Rotax 912/914 (7610-003) with eyelet end to the Throttle Arm bolt. Route Cables through support arm slots. Install
Bolt AN3-15A with one cable on left side and one on right side. Bolt AN3-15A, Washer AN3, Throttle Cable, Tube, Throttle Cable, Washer
AN3, Nut AN3, and tighten.
26.2 Zip tie the cables to center support tube. Note: Route left cable to left carburetor and right cable to right carburetor (from throttle location).
26.3 Route Cables up behind the bulkhead through the pylon, down the Root Tube to the motor carburetors.

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 Section 31, Motor Assembly, SeaRey, LSA

Cable Support

Throttle Cable

Throttle Arm
Throttle Cable Throttle Cable

Figure 27. Installing Throttle Cables to the Carburetors

Note: Make sure Throttle Handle is closed (rear) when making the connection

27.1 Slide the Cable through the aft end cable support on the carburetor and seat the cable shroud. Run Cable to the Throttle Arm on carburetor
and connect to bolt by pushing through the hole in the bolt. Insert bolt into arm and tighten nut. Set Tension.

Note: Zip Tie the cables on top of the motor on all curves, preventing any movement in cable position

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 Section 31, Motor Assembly, SeaRey, LSA

Zip Tie Hole

Spring
Wire

Wire

Trim Sensor Trim Sensor Trim Slave Arm

Figure 28. Installing Trim Position Sensor

28.1 Adjust Spring, 7/16” x 6 3/16” (5750-006) to make sure the spring remains straight through the travel path
28.2 Drill Hole in the outboard trim slave arm 1-1/4” down and 1/2” to forward side. Insert the Piano Wire (1710-051) in the hole in the Slave Arm and
the Trim Sensor arm. Attach the Trim Position Sensor (POS-12) on the top of the Electric Motor with double-sided tape and a zip tie around sensor
and Trim motor.

Note: Operate the Trim Motor and check the travel of the wire. Adjust as needed.

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 Section 31, Motor Assembly, SeaRey, LSA

Hole

Electric Flap
Actuator Horn

Wire

Rivet
Flap Sensor

Figure 29. Installing Flap Position Sensor

29.1 Drill Hole in the Electric Flap Actuator Horn. Insert the Piano Wire (1710-051) in the hole in the Horn and the Trim Sensor arm. Attach the Flap
Position Sensor (POS-12) onto the Root Support, Mid with (2) Rivets, SBL44.

Note: Operate the Trim Motor and check the travel of the wire. Adjust as needed.

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 Section 31, Motor Assembly, SeaRey, LSA

Rivet

Headset Jack Headset Jack

Plate Plate

Figure 30. Installing Headset Jack Plates

30.1 Install Headset Jack Plate (1510-273) on Root Tube Mid, co-pilot side, as far down as possible. Drill 3/16” hole through pre-drilled holes in the
Headset Jack Plate into the Root Tube Mid. Install (2) Rivet Rivet AB6-4A (P-64).
30.2 Install Plate on Root Tube Mid, pilot side, a little further up the Root Tube about half the width of the Plate. Drill 3/16” hole through pre-drilled
holes in the Plate into the Root Tube Mid. Install (2) Rivet AB6-4A (P-64).

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 Section 31, Motor Assembly, SeaRey, LSA

Metal Band
ELT Cable &
Data Cable

Rivet

ELT Mount ELT Mount

Plate Plate
ELT

Figure 31. Installing the ELT

31.1 Drill (2) 1/8” holes on the centerline of the ELT Mount Plate.
31.2 Lay the ELT on the Boom Tube just behind the Forward Root Support at 9” back to the front of the ELT Mount Plate.
31.3 Mark the (2) 1/8” holes onto the Boom Tube. Drill 1/8” holes.
31.4 Rivet the Mount Plate down with Rivet SBL44.
31.5 Install the ELT into the Mount Plate and secure with the metal band. Plug in ELT cable and data cable.

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 Section 31, Motor Assembly, SeaRey, LSA

Static Port
retainer Nut

Hose

Static Port
Static Port

Figure 32. Installing the Static Ports

32.1 Find location of Static Port (1510-001): 10” forward of the Allen bolt for Windshield Tube forward and 2” down from the bottom edge of the
Nose Deck.
32.2 Drill a 1/4” hole through the Hull at the above-marked location.
32.3 Insert the Static Port from the outside. On the inside install Washer AN4, and 1/4-20 Jam Nut.
32.4 Tighten nut. Install Hose, ¼” ID x 3/8” Vinyl onto the Static Port barb. Run all hose to connect the Static Ports back to the instruments.

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 Section 31, Motor Assembly, SeaRey, LSA

Screw Panel #6 Cover

Bracket Aft Panel #6 Cover

Figure 33. Installing the Panel #6 Cover

33.1 Install Nutplate 1/4-28 (NP1/4-28) onto Radiator Bracket Forward (7530-008) using Rivet, CCR-264-SS-3-5 (264CR35).
33.2 Drill 3/16” Hole into the Power Panel #6 1-1/2” up from bottom front.
33.3 Install Radiator Bracket onto the Power Panel with Bolt AN4-05A, Washer AN4, Radiator Bracket, Panel, Washer AN4, Nut AN4, and tighten.
33.4 Install clear Panel #6 Cover (1100-020) on top of Brackets with (2) machine screw 1/4-28 x 1/2” (S050-1428) on each end.

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 Section 31, Motor Assembly, SeaRey, LSA

Spinner

Propeller

Figure 34. Installing of the Warp Drive Propeller

34.1 Propeller Installation: (See Warp Drive manual, HPL—R Hub Assembly Instructions – 06.01.10), Propeller, WARP DRIVE 3 BLADE 68-L,
CF/NICKEL LE/TAPER (7220-044), WARP DRIVE 5" SPINNER POLISHED ALUMINUM (7220-045), WARP DRIVE MOUNTING HARDWARE
8x75 W/DRILLED HEADS (7220-046)
34.2 Set the propeller blade angle at 14 degrees for a good starting point.

Note: Safety Wire bolts on Propeller when complete

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