RAFSA - CONMAN SECTION 7 - PRODUCT NOTICES

RAF2000
PRODUCT NOTICES

RAF2000 GTX SE FI 2.5

ISSUE: 10/2015

ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD

PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
Web: www.rafsa.co.za Company Reg No: 2007/012378/07
Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-01
RAF 2000 GYROPLANE

NO. 1: CONTROL TUBE CRACKED WELD

A pilot, owner observed a cracked weld on the control tube, where the pivot straps are welded to the control tube
(SEE FIG. 7, A).

The weld initially, was welded around the bottom and spot welded on the top.

It is recommended that the weld be continuous around the top and bottom of the pivot straps on the control tube.

Owners can have the welding done by someone of their choice, or can ship the control assemble to the R.A.F.
factory prepaid, and have it welded at no charge, and it will be returned on a collect basis.

If your control tube has a continuous weld around the tip and bottom of the pivot straps on the control tube there is
no need to return it to the factory.

Time on the aircraft was approximately 200 hours.

NOTE: THIS AIRCRAFT PRODUCT NOTICE AFFECTS ALL SERIAL NUMBERS PRIOR TO AND INCLUDING
SERIAL NO. H2-90-1-28.

Issue Date: March 1992 Revision Date: 17 Aug 2011 Revision No: 002
Page 1



ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD

PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
Web: www.rafsa.co.za Company Reg No: 2007/012378/07
Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-01
RAF 2000 GYROPLANE

NO. 2: KEYED START SWITCH

R.A.F. 2000 GYROPLANE

An incidence has occurred, where the RAF 2000 Gyroplane has had an unscheduled engine start, thereby,
creating an unsafe condition for the owner and possible bystanders.

The factory recommends that the owners install a keyed switch to prevent any unscheduled turning over of the
engine.

This Aircraft Product Notice No.2 Outlines Good Aircraft Safety Procedures.

Issue Date: March 1992 Revision Date: 17 Aug 2011 Revision No: 002
Page 1

ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD

PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
Web: www.rafsa.co.za Company Reg No: 2007/012378/07
Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-03
RAF 2000 GYROPLANE

NO. 3: EA82 SUBARU ENGINE CAM IDLERS

R.A.F. 2000 GYROPLANE

It has come to our attention that the cam idlers (idlers with a flat face-with a flange) outer cover can slide off the
bearing once a certain operating temperature is reached.

To avoid this from possibly happening in flight. We have drilled 4 - 1/8" holes 90 degrees apart around the
periphery of the inside of the cam idler. Only drill through the outside wall of the cam idler.

Select a small 1/8" punch and insert through the holes and make a small dimple on the inside wall in 4 places. See
figure.

*NOTE: Before disassembly you must make sure that the timing belt does not move on the crank shaft or the cam
sprockets. To achieve this take a white paint stick and make a mark on one cam sprocket tooth and onto the belt
then make a mark from the crank sprocket onto the belt. Only remove one idler at a time make the change then
reinstall the idler and tighten the belts and bolts to the recommended torque values in the Subaru technical manual.

*NOTE: Do not move the crank shaft or cam shaft while the idler is removed. Serious internal damage can occur if
the crank shaft is rotated with the cam idler removed.

THIS AIRCRAFT PRODUCT NOTICE AFFECTS ALL SERIAL NUMBERS PRIOR TO AND INCLUDING SERIAL
NO. H2-90-1-28.

Issue Date: March 1992 Revision Date: 17 Aug 2011 Revision No: 002
Page 1



ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD

PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
Web: www.rafsa.co.za Company Reg No: 2007/012378/07
Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-04
RAF 2000 GYROPLANE

NO. 4: RADIATOR

R.A.F. 2000 GYROPLANE

The radiator is new, however, they are modified to suit the installation for the RAF 2000 gyroplane. These
modifications are completed out-of-house.

We would advise that you pressure test the radiator for leaks as well as flush out the radiator thoroughly before
installing on the gyroplane.

This procedure will ensure that you will have no problems after the installation.

*NOTE: THIS AIRCRAFT PRODUCT NOTICE DOES NOT HAVE AN EXPIRY DATE IT IS A
PROCEDURE THAT MUST BE OBSERVED.

Issue Date: March 1992 Revision Date: 17 Aug 2011 Revision No: 002
Page 1

ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD

PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
Web: www.rafsa.co.za Company Reg No: 2007/012378/07
Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-05
RAF 2000 GYROPLANE

NO. 5: COIL BRACKET

RE: OWNERS OF THE RAF GYROPLANES WITH SUBARU ENGINES MODEL EA82

A recent incident involving the factory gyroplane was attributed to a broken gear clamp which held the coil this
subsequently shorted out the coil.

The failure occurred in the gear clamp which held the coil to the aluminium bracket which extends up from the
head.

A possible remedy is to replace the gear clamp every 50 hours or less.

ROTARY AIR FORCE has a new welded bracket clamp for sale for the cost of $15 or you may construct the
bracket following the enclosed three part drawing.

Your prompt response to this matter is appreciated. Should you require further assistance please feel free to call
the factory.
Thank you for your co-operation in maintaining a safe flying aircraft.

Best of luck and good flying.

*NOTE: THIS AIRCRAFT PRODUCT NOTICE AFFECTS ALL SERIAL NUMBERS PRIOR TO AND
INCLUDING SERIAL NO. H2-90-1-28.

Issue Date: 5 March 1992 Revision Date: 17 Aug 2011 Revision No:
002 Page 1



ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD

PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
Web: www.rafsa.co.za Company Reg No: 2007/012378/07
Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-06
RAF 2000 GYROPLANE

NO. 6: GIMBLE HEAD MOVEMENT

Owners should ensure that proper movement of the Gimble Head is maintained.

LATERAL MOVEMENT LEFT from center should be a full 12 degrees.

LATERAL MOVEMENT RIGHT from center should be a full 12 degrees.

FORE MOVEMENT should be -1 or -2 degrees.

AFT MOVEMENT should be a full 19 - 20 degrees.

This LATERAL, and FORE and AFT movement should ensure proper control in flight.

*NOTE: THIS AIRCRAFT PRODUCT NOTICE DOES NOT HAVE AN EXPIRY DATE IT IS A
PROCEDURE THAT MUST BE OBSERVED.

Issue Date: 5 March 1992 Revision Date: 17 Aug 2011 Revision No:
002 Page 1

ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD

PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
Web: www.rafsa.co.za Company Reg No: 2007/012378/07
Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-07
RAF 2000 GYROPLANE

NO. 7: 350 CFM CARBURETOR, and 500 CFM CARBURETOR

It has come to our attention that the 350 CFM is over fuelling in the mid range RPM.

To identify the 350 CFM CARBURETOR from the 500 CFM CARBURETOR look on the right hand side of the
Carburettor (throttle side). If your Carburettor has a black plastic accelerator pump arm this is the 350 CFM
CARBURETORS.

If the carburettor has a metal accelerator pump arm this is the 500 CFM CARBURETORS.

The change up to rectify the over fuelling on the 350 CFM CARBURETORS is as follows:

Remove the 4 bolts holding the float bowl to the carburetor. Remove the float bowl. Remove the metering block.
Change the jets from 61 to 66. *NOTE: BOTH JETS MUST BE CHANGED.

Turn the block over. In the middle of the block between the jets is the power valve. Remove the power valve with a
1" wrench. Cut out all of the inside parts of the power valve, leaving only the outside housing. Fill up the inside of
the power valve with steel filled epoxy. Allow to fully cure.

Reinstall the power valve in the metering block. Install the metering block and fuel bowl in the reverse order of
removal.

After the installation of the float bowl, turn on the fuel pump and check for leaks.

The 500 CFM CARBURETOR is over fuelling at full power.

The change up to rectify the over fuelling on the 500 CFM CARBURETORS is as follows:

Remove the 4 bolts holding the float bowl to the carburettor. Remove the float bowl. Remove the metering block.
Change the jets from 70 to 73. *NOTE: BOTH JETS MUST BE CHANGED.

Turn the block over. In the middle of the block between the jets is the power valve. Remove the power valve with a
1" wrench. Cut out all of the inside parts of the power valve, leaving only the outside housing. Fill up the inside of
the power valve with steel filled epoxy. Allow to fully cure.

Reinstall the power valve in the metering block. Install the metering block and fuel bowl in the reverse order of

Issue Date: 26 February 1993 Revision Date: 17 Aug 2011 Revision No: 002

Page 1

ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD

PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
Web: www.rafsa.co.za Company Reg No: 2007/012378/07
Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-07
RAF 2000 GYROPLANE

removal.

After the installation of the float bowl, turn on the fuel pump and check for leaks.

ROTARY AIR FORCE assures you that further testing is on-going to ensure that you are properly informed as to
the proper care and feeding of your SUBARU ENGINE. In so doing, you will have many trouble free hours of
operation.

*NOTE: THIS AIRCRAFT PRODUCT NOTICE AFFECTS ALL SERIAL NUMBERS PRIOR TO AND
INCLUDING SERIAL NO. H2-90-1-28.

Issue Date: 26 February 1993 Revision Date: 17 Aug 2011 Revision No: 002
Page 2

ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD

PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
Web: www.rafsa.co.za Company Reg No: 2007/012378/07
Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-08
RAF 2000 GYROPLANE

NO. 8: REPLACEMENT OF JACK SHAFT

R.A.F. 2000 GYROPLANE

February 26, 1993

AIRCRAFT PRODUCT NOTICE:

If your RAF 2000 gyroplane is involved in an incident where the aircraft is rolled on it's side causing the propeller to
shatter, it is necessary for the JACK SHAFT to be REPLACED.

*NOTE: THIS AIRCRAFT PRODUCT NOTICE DOES NOT HAVE AN EXPIRY DATE IT IS A
PROCEDURE THAT MUST BE OBSERVED.

Issue Date: 26 February 1993 Revision Date: 17 Aug 2011 Revision No: 002
Page 1

ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD

PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
Web: www.rafsa.co.za Company Reg No: 2007/012378/07
Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-09
RAF 2000 GYROPLANE

NO. 9: COIL

ROTARY AIR FORCE would like to bring to your attention that the coils are failing due to the engine heat and
vibration.

SUGGESTIONS

1. The coil can be moved onto the lower engine mount (straight down from its original position) It will
be necessary to run a longer coil wire.

The lower engine mount is a stationary platform for the coil away from the heat and vibration of the
engine.

2. As an extra precaution you could rubber mount the coil and bracket.

3. Use an ACCEL COIL No. 140008, they are an electronic coil This type of coil should give a better
service life and a hotter spark.

The ACCEL COIL is not currently supplied with the RAF 2000 kit.

*NOTE: THIS AIRCRAFT PRODUCT NOTICE AFFECTS ALL SERIAL NUMBERS PRIOR TO AND
INCLUDING SERIAL NO. H2-93-4-77.

Issue Date: 12 April 1993 Revision Date: 17 Aug 2011 Revision No: 002
Page 1

ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD

PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
Web: www.rafsa.co.za Company Reg No: 2007/012378/07
Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-10
RAF 2000 GYROPLANE

NO. 10: 3/16" RING GEAR FLEX PLATE

The 3/16" Ring Gear c/w Flex Plate is oil caning during acceleration and deceleration of the engine. Thus the Ring
Gear c/w Flex Plate will fail prematurely. Therefore, it will be necessary to conduct regular inspections of the Ring
Gear c/w Flex Plate around the bottom sprocket.

ROTARY AIR FORCE has redesigned the INTERFACE HUB and can provide a new, larger Interface Hub. The
new Interface Hub has larger surface and should prevent this situation from reoccurring.

If your Ring Gear c/w Flex Plate is CRACKED it will need to be replaced.

Your Ring Gear c/w Flex Plate can be returned to the factory (PRE-PAID) for a $15 core value (just deduct $15
from the purchase price).

Rotary Air Force will replace your INTERFACE HUB and RING GEAR C/W FLEX PLATE for $160 plus
shipping.

CORE RING GEAR C/W FLEX PLATE $-15.00
RING GEAR C/W FLEX PLATE 85.00
INTERFACE HUB 75.00

TOTAL COST WITH CORE RING GEAR C/W FLEX PLATE $145.00

*NOTE: THIS AIRCRAFT PRODUCT NOTICE AFFECTS ALL SERIAL NUMBERS PRIOR TO AND INCLUDING
SERIAL NO. H2-93-4-77.

Issue Date: 12 April 1993 Revision Date: 17 Aug 2011 Revision No: 002
Page 1

ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD

PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
Web: www.rafsa.co.za Company Reg No: 2007/012378/07
Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-11
RAF 2000 GYROPLANE

NO. 11: TEMPORARY SPEED RESTRICTION

AIRCRAFT PRODUCT NOTICE:

A speed restriction of 70 MPH is imposed on the RAF 2000 gyroplane until a reinforcement strip is added to the
cabin enclosure to strengthen the lexan windscreen.

A situation could exist were the lexan could collapse in at high speeds. This situation is greater when the RAF
2000 gyroplane is flown without the cabin doors.

You will receive from the factory at the earliest possible date a fibreglass support to install inside the cabin
enclosure to strengthen the lexan windscreen.

After the fibreglass support is installed the speed restriction is lifted.

The fibreglass support will be supplied by the factory, however the customer will be responsible for the shipping
costs, and any customs or duties.

*NOTE: The NO CHARGE fibreglass support supplied by the factory, only applies to the ORIGINAL
RAF 2000 GYROPLANE OWNER.

*NOTE: THIS AIRCRAFT PRODUCT NOTICE AFFECTS ALL SERIAL NUMBERS PRIOR TO AND
INCLUDING SERIAL NO. H2-93-4-90.

Issue Date: 1 June 1993 Revision Date: 17 Aug 2011 Revision No: 002
Page 1

ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD

PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
Web: www.rafsa.co.za Company Reg No: 2007/012378/07
Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-12
RAF 2000 GYROPLANE

NO. 12: AIRCRAFT PRODUCT NOTICE, RAF 2000 GYROPLANE

1. PRE-FLIGHT AND POST-FLIGHT INSPECTION OF HUB BAR Pre-flight and Post-flight inspections must
be conducted on the HUB BAR to ensure that all of the bolts remain tight. Along with the pre-flight and
post-flight inspections follow proper rotor blade management while taxing over rough terrain or transporting
the rotor blades.

The HUB BAR is a HIGH STRESS COMPONENT and MUST be inspected before each flight for any stress
cracks which may occur over time. The most vital areas are shown in the following drawing of the HUB
BAR. Inspect for the possibility of development of stress cracks or the propagation of cracks in these
areas. If cracks occur the HUB BAR must be replaced before any further flights are made.

There have been 2 incidence where cracking has occurred in the HUB BAR. Both HUB BARS had in
excess of 200 hours.

MANDATORY RECALL, RAF 2000 GYROPLANE, NO. 13, HUB BAR. All HUB BARS MUST be returned
to the ROTARY AIR FORCE FACTORY, COMPLETE, effective immediately. ROTARY AIR FORCE will
inspect and replace the center section and RESET the HUB BAR (there will be a nominal charge). This
recall is mandatory and must be complied with. This recall affects all rotor blade shipments received prior
to August 11, 1994.

2. HIGH PERFORMANCE BELT DRIVEN PRE-ROTATOR, HEAVY DUTY CABLE It has been brought to
our attention that the outer cable jacket pulled out of the crimped ferrule. There has only been one such
incident, however, to prevent the cable from dropping into the propeller the outer jacket MUST be safety
tied as per the following drawing. This service bulletin affects all RAF 2000 gyroplanes that have the HIGH
PERFORMANCE BELT DRIVEN PRE-ROTATOR with the heavy duty inner and outer cable.

3. EA82 SUBARU ENGINE BREAK-IN TIME As you are aware the Subaru engine you received was a rebuilt
engine. This engine must be broke-in over an appropriate length of time. Rotary Air Force utilized the
industry best in chrome rings which were installed into your engine. These rings are very strong and
require a longer break-in period of a least 20 hours before you should try and run the engine at maximum
RPM. A shorter break-in time is resulting in the rings not seating in properly and causing the cylinders to
glaze over. Thus the engines are failing prematurely. This service bulletin affects all RAF 2000 gyroplanes
up to and including Serial No. H2-94-5-127. Engines after this Serial No. will have cast rings so that the
break-in period should be somewhat shorter. *NOTE: Minimum water temperature on engine break-in
MUST be 180 - 200. Cover radiator if need be.

Issue Date: 11 August 1994 Revision Date: 17 Aug 2011 Revision No: 002

Page 1

ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD

PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
Web: www.rafsa.co.za Company Reg No: 2007/012378/07
Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-12
RAF 2000 GYROPLANE

4. PRE-FLIGHT AND POST-FLIGHT INSPECTION OF STARTER RING GEAR The welds on the starter ring
gear may break free after prolonged use. An inspection of all welds MUST be conducted before and after
all flights. The owner/operator may replace or repair at their own discretion.

ROTARY AIR FORCE has designed a new RING GEAR ASSEMBLY which you may purchase. The FLEX
PLATE is now made as a complete unit of 1/2" aluminum with the ring gear pressed onto the flex plate.
This will eliminate the problem of the welds breaking as well as the problem of oil canning. You may
change up to the new flex plate for $175.00 Canadian funds.

ROTARY AIR FORCE has been shipping out the new style of FLEX PLATE for some time now, however,
an inspection of your gyroplane will determine if you have the latest FLEX PLATE. Should you have an old
style STARTER RING GEAR ensure that the pre-flight and post-flight inspection is followed.

5. JACKSHAFT REPLACEMENT If your RAF 2000 gyroplane is involved in an incident where the aircraft is
rolled on it's side causing the propeller to shatter, it is necessary for the JACKSHAFT to be REPLACED. It
is also necessary to magnaflux the crankshaft. To neglect this procedure could result in a future
unscheduled engine out or losing the propeller and upper sprocket in flight.

6. PRE-FLIGHT AND POST-FLIGHT INSPECTION OF 3/16" REAR DRIVE PLATE The 3/16" REAR DRIVE
PLATE is cracking where the alternator is mounted as per the following drawing.

7. NOTIFY THE FACTORY if you have sold the RAF 2000 gyroplane. This is necessary so that our files can
be updated with the new owners name and address.

*NOTE: ADD THIS AIRCRAFT PRODUCT NOTICE AND DRAWINGS TO THE FLIGHT MANUAL AND
*NOTE: OPERATIONS LIMITATIONS MANUAL.

AIRCRAFT PRODUCT NOTICE NO. 12 OUTLINES GOOD AIRCRAFT SAFETY PROCEDURES.
FOLLOW THESE PROCEDURES DURING PRE-FLIGHT AND POST-FLIGHT INSPECTIONS.

Issue Date: 11 August 1994 Revision Date: 17 Aug 2011 Revision No: 002
Page 2





ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD

PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
Web: www.rafsa.co.za Company Reg No: 2007/012378/07
Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-13
RAF 2000 GYROPLANE

NO. 13: MANDATORY RECALL, RAF 2000 GYROPLANE, HUB BAR

All HUB BARS MUST be returned to the ROTARY AIR FORCE FACTORY, COMPLETE, effective immediately.

ROTARY AIR FORCE will inspect and replace the center section and RESET the HUB BAR.

This recall is mandatory and must be complied with. This recall affects all rotor blade shipments received prior to
August 11, 1994.

PROCEDURE:

1. RETURN THE COMPLETE HUB BAR. *NOTE: DO NOT REMOVE TENSION STRAPS FROM ROTOR
BLADES. Mark with a felt marker on the center section of the HUB BAR the number of hours that the HUB
BAR has been in service and the Serial No. of the ROTOR BLADE.

2. Return the HUB BAR to ROTARY AIR FORCE MARKETING INC., 1107 - 9TH STREET WEST, BOX 1236,
KINDERSLEY, SASKATCHEWAN, CANADA, S0L 1S0, TEL:306-463-6030, FAX:306-463-6032 by UPS or
the postal system.

*NOTE: CANADIAN SHIPMENTS, Place the value at $300.00.

*NOTE: US AND INTERNATIONAL SHIPMENTS, On your export documents place the value at $300.00
Canadian and state CANADIAN GOODS RETURNING FOR REPAIR. It would be helpful if you could
quote the way bill number assigned to your shipment when you received your rotor blade shipment.

ALL SHIPPING COSTS are the responsibility of the RAF 2000 owner. For shipments returning to the
United States or International the freight, if necessary, will be pre-paid and invoiced. Canadian shipments
will be sent out freight collect.

COST 50.00
ANODIZING 150.00
SET-UP AND HANDLING CHARGE $200.00
TOTAL

Send cheque, money order, or supply visa or master card number with expiry date and your name as it
appears on the card.

Issue Date: 11 August 1994 Revision Date: 17 Aug 2011 Revision No: 002

Page 1

ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD

PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
Web: www.rafsa.co.za Company Reg No: 2007/012378/07
Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-13
RAF 2000 GYROPLANE

3. All new ROTOR BLADE shipments will have the new beefier HUB BAR center section. Effective August
11, 1994. Therefore, if you have received your rotor blade prior to August 11, 1994 the HUB BAR falls
under this mandatory recall.

4. The new HUB BAR will be shipped out on a first come first served basis.

5. Your HUB BAR will be RESET with the new centre section and the parts from your HUB BAR and returned
to you.

*NOTE: All new ROTOR BLADE shipments will have the new beefier HUB BAR center section.
EFFECTIVE AUGUST 11, 1994. Therefore, if you have received your rotor blade prior to
August 11, 1994 the HUB BAR falls under this mandatory recall.

Issue Date: 11 August 1994 Revision Date: 17 Aug 2011 Revision No: 002
Page 2

ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD

PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
Web: www.rafsa.co.za Company Reg No: 2007/012378/07
Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-14
RAF 2000 GYROPLANE

NO. 14: BREAK-IN TIME CHANGE FOR EA 82 SUBARU ENGINE, INCREASE NUMBER OF HOURS TO 20

ROTARY AIR FORCE has allowed for a maximum of 36 to 38 advanced timing using 93 octane or higher fuel.

Unauthorized adjustment of the timing or the use of a lower octane fuel or both of these components together will
result in a condition called "DETONATION". The result will be broken ring lands and the pumping out of large
quantities of oil through the blow by tubes.

You MUST NOT adjust the timing past the 36 to 38 advanced timing allowed for.

You MUST use a 93 octane or higher fuel.

You MUST break in the engine for the period of 20 hours as recommended by the factory.

ROTARY AIR FORCE will not be responsible if you do not follow these instructions to the letter for the EA82
SUBARU ENGINE.

The oil selected by the RAF factory is SHELL 10W-30 multi-grade.

*NOTE: DO NOT USE SYNTHETIC OIL FOR THE BREAK IN PERIOD. IT IS NOT RECOMMENDED BY
THE FACTORY TO USE SYNTHETIC OIL BEFORE 25 - 30 HOURS OF BREAK IN TIME FOR
THE EA 82 SUBARU ENGINE. *CAUTION: USING SYNTHETIC OIL SOONER THAN 25 - 30
HOURS WILL CAUSE THE RINGS TO NOT SEAT PROPERLY.

1. Start engine and run at an idle until water temperature is about 130 - 140 degrees F. *NOTE: CAUTION
MUST BE TAKEN TO ENSURE THAT ALL AIR IS BLED FROM THE COOLING SYSTEM.

2. Run engine up to 3500 RPM for 20 seconds, then idle engine, then run engine back up to 3500 RPM keep
doing this for about 2 hours.

3. Next run the engine at 2500 - 3500 RPM for about 10 hours. After 7 hours DRAIN oil and REPLACE filter.
Fill with clean oil 10W-30 or 10W-40.

4. As engine breaks in keep increasing the RPM to 4000, then idle, then back up to 4000 RPM keep doing
this for about 8 hours.

Issue Date: 02 May 1995 Revision Date: 17 Aug 2011 Revision No: 002
Page 1

ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD

PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
Web: www.rafsa.co.za Company Reg No: 2007/012378/07
Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-14
RAF 2000 GYROPLANE

5. At 20 hours DRAIN oil and REPLACE filter. Fill with clean oil 10W-30 or 10W-40.
6. Start engine and check for leaks. Full throttle checks can be done after 20 hours of break-in time.

*NOTE: THIS AIRCRAFT PRODUCT NOTICE NO. 14 AFFECTS ALL RAF 2000 GYROPLANES WITH
THE EA 82 SUBARU ENGINE INSTALLATION.

Issue Date: 02 May 1995 Revision Date: 17 Aug 2011 Revision No: 002
Page 2



ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD

PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
Web: www.rafsa.co.za Company Reg No: 2007/012378/07
Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-15
RAF 2000 GYROPLANE

NO. 15: ELECTRICAL INSTALLATION PRACTICES

*CAUTION: IMPROPER INSTALLATION OF ELECTRICAL COMPONENTS WILL CAUSE PREMATURE
FAILURE. PRE-CAUTION MUST BE TAKEN TO MINIMIZE THE DAMAGE THAT WILL BE
CAUSED BY IMPROPER INSTALLATION METHODS.

RAF 2000 GYROPLANE ELECTRICAL CONNECTIONS ON THE ENGINE ARE PRONE TO BREAKAGE.
Therefore you MUST FOLLOW THE PROPER ELECTRICAL PRACTICES.

You MUST ensure that the wires are supported by some means and then use some vibration damping such as a
silicone base, or rubber mount, or coiling the wire around a screw driver then setting the wire in silicone. This will
ensure that the vibrations are taken up in that area and not at the connection.

Pre-mature failure of the coil continues to be a problem. Follow the above suggestion for electrical installation
practices and review a previous PRODUCT NOTICE NO. 9 COIL. REPRINTED AS FOLLOWS:

ROTARY AIR FORCE PRODUCT NOTICE NO. 9 COIL
PRODUCT NOTICE
APRIL 12, 1993

NO. 9: COIL

ROTARY AIR FORCE would like to bring to your attention that the coils are failing due to the engine heat and
vibration.

1. The coil MUST BE moved onto the lower engine mount (straight down from its original position) It will be
necessary to run a longer coil wire.

The lower engine mount is a stationary platform for the coil away from the heat and vibration of the engine.

2. As an extra precaution rubber mount the coil and bracket. You MUST ensure that the wires are supported
by some means and then use some vibration damping such as a silicone base, or rubber mount, or coiling
the wire around a screw driver then setting the wire in silicone. This will ensure that the vibrations are
taken up in that area and not at the connection.

Issue Date: 02 May 1995 Revision Date: 17 Aug 2011 Revision No: 002
Page 1

ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD

PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
Web: www.rafsa.co.za Company Reg No: 2007/012378/07
Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-15
RAF 2000 GYROPLANE

3. Use an ACCEL COIL No. 140008, they are an electronic coil This type of coil should give a better service
life and a hotter spark. The ACCEL COIL is not currently supplied with the RAF 2000 kit.

*NOTE: AIRCRAFT PRODUCT NOTICE NO. 15 OUTLINES GOOD AIRCRAFT INSTALLATION
PROCEDURES. FOLLOW THESE PROCEDURES DURING CONSTRUCTION AND CHECK
ELECTRIC CONNECTIONS DURING PRE-FLIGHT AND POST-FLIGHT INSPECTIONS.

Issue Date: 02 May 1995 Revision Date: 17 Aug 2011 Revision No: 002
Page 2

ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD

PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
Web: www.rafsa.co.za Company Reg No: 2007/012378/07
Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-16
RAF 2000 GYROPLANE

NO. 16: ROTOR BLADE STRIKES

ROTOR BLADES are an extremely critical component and must be handled with extreme care and caution.

Proper ROTOR BLADE maintenance and operation is a MUST. Follow guidelines as outlined in the FLIGHT MANUAL
AND OPERATING LIMITATIONS MANUAL.

If the RAF 2000 GYROPLANE is involved in an incident where the ROTOR BLADES contact the ground or an obstacle
while in rotation the kinetic energy is displaced somewhere in the ROTOR SYSTEM.

Due to the impossibility of pinpointing the area of stress the ENTIRE rotor system, rotor blades, tension straps, hub bar
etc. MUST BE COMPLETELY REPLACED.

This is a precaution which can prevent a catastrophic failure of the ROTOR SYSTEM due to stress introduced during an
incident.

*NOTE: AIRCRAFT PRODUCT NOTICE NO. 16 OUTLINES GOOD ROTORCRAFT SAFETY PROCEDURES.
FOLLOW THESE PROCEDURES SHOULD THE ROTOR SYSTEM CONTACT THE GROUND OR
AN OBSTACLE.

Issue Date: 02 May 1995 Revision Date: 17 Aug 2011 Revision No: 002
Page 1

ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD

PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
Web: www.rafsa.co.za Company Reg No: 2007/012378/07
Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-17
RAF 2000 GYROPLANE

NO. 17: TIME CHANGE COMPONENTS

1. The RUBBER MAST BUSHING is a replaceable TIME CHANGE component and should be included as part of
your pre-flight inspections.

The inspection of the RUBBER MAST BUSHING should be carried out periodically (EXAMPLE: EVERY 5TH
FLIGHT).

To inspect the RUBBER MAST BUSHING simply remove the upper 1/2" bolt which goes through the center of
the mast. If the rubber is deteriorated at all then you MUST REPLACE this RUBBER MAST BUSHING before
further flights are made.

2. 2" X 2" X 1/8" TUBES RIVETED BETWEEN CHEEK PLATES are replaceable TIME CHANGE components
and should be included as part of your pre-flight inspections.

After a number of pre-rotations these tubes can crack this has only been observed in high time AIRCRAFT,
however, inspection of the 2" X 2" X 1/8" TUBES RIVETED BETWEEN CHEEK PLATES should be carried out
periodically (EXAMPLE: EVERY 50 HOURS).

*NOTE: AIRCRAFT PRODUCT NOTICE NO. 17 OUTLINES A TIME CHANGE COMPONENTS.

ADD THE INSPECTION OF THE RUBBER MAST BUSHING AND 2" X 2" X 1/8" TUBES RIVETED
BETWEEN CHEEK PLATES TO YOUR PERIODIC PRE-FLIGHT AND POST-FLIGHT
INSPECTIONS.

Issue Date: 17 May 1995 Revision Date: 17 Aug 2011 Revision No: 002
Page 1

ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD

PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
Web: www.rafsa.co.za Company Reg No: 2007/012378/07
Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-18
RAF 2000 GYROPLANE

NO. 18: HUB BAR MOVEMENT

In reference to the HUB BAR MOVEMENT, when you install your rotor blades tilt the rotor blades fore and aft the HUB
BAR MUST contact on the 1/4" BEARING RETAINER PLATE.

However, if the HUB BAR is contacting the CENTER BOLT instead of the 1/4" BEARING RETAINER PLATE then remove
the HUB BAR, mark your CHORDWISE BLOCK for placement then remove the CHORDWISE BLOCK. Have 30 thou
shaved off the bottom of the CHORDWISE BLOCK than replace it back in the same position on your HUB BAR.

Replace your bolts making sure to use extra washers under the nuts so as not to thread bind the bolt. Remember you
should have 1 1/2 to 3 threads showing above your nut.

*NOTE: REMEMBER if you remove a niloc nut you should not reuse the same nut more than twice.

*NOTE: THIS AIRCRAFT PRODUCT NO. 18: HUB BAR MOVEMENT NOTICE AFFECTS ALL SERIAL
NUMBERS PRIOR TO AND INCLUDING SERIAL NO. H2-95-6-169.

Issue Date: 24 August 1995 Revision Date: 17 Aug 2011 Revision No: 002
Page 1

ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD

PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
Web: www.rafsa.co.za Company Reg No: 2007/012378/07
Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-19
RAF 2000 GYROPLANE

NO. 19: IMPROPER OR NO SUPPORT OF ROTOR BLADES WHILE GYROPLANE IS STORED OUT OF
DOORS.

It has come to our attention that some gyroplanes are being stored out of doors without proper support under the
rotor blades. It has been shown that if a wind comes up and the rotor blades are allowed to flex up and down that
this puts extreme bending moments on the hub bar. If allowed to go unchecked the modulus of elasticity may be
reached. This is to say that if you take a piece of metal and bend it far enough that the material will not return to its
former position (memory has been lost). A rotor blade allowed to flex like this can lead to fatigue cracking much like
a piece of metal that has been bent to many times will exhibit fatigue cracking.

This condition does not exist while the gyroplane is in flight. Centrifugal force of the rotor blades keeps the bending
moment of the hub bar to less than 1/2  while in flight. The rotor blade allowed to flex in the wind while not spun up
has been shown to bend up to 3 .

Proper care and attention must be paid to ensure that this condition does not happen if the gyroplane is stored out
of doors. Rotor blades must be supported properly or removed from the gyroplane.

Proper care and attention must also be taken before taxing over rough terrain. Rotor blades must be spun up to at
least 120 R.P.M. before taxing over any rough terrain.

Proper care and attention must be taken to inspect the hub bar for any nicks or deep scratches where stress can
accumulate. Any nicks or deep scratches must be sanded out so that stress will not accumulate at these points.

Proper pre-flight and post-flight inspection of the hub bar, gimble head, control systems, and control surfaces are a
must to ensure safe flight.

*NOTE: AIRCRAFT PRODUCT NOTICE NO. 19 OUTLINES PROCEDURES TO FOLLOW DURING
STORAGE AND DURING PRE-FLIGHT AND POST-FLIGHT INSPECTIONS OF THE HUB BAR
AND ROTOR BLADES.

Issue Date: 1 November 1995 Revision Date: 17 Aug 2011 Revision No: 002
Page 1

ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD

PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
Web: www.rafsa.co.za Company Reg No: 2007/012378/07
Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-20
RAF 2000 GYROPLANE

NO. 20: EA82 SUBARU ENGINE PROPELLER/REDUCTION DRIVE SHAFT (JACKSHAFT).

It has come to our attention that the RAF 2000 owners with the EA82 SUBARU ENGINE have been adjusting the
drive belt to tight. This adjustment is a critical adjustment. The belt must be adjusted so that there is between 1 to
1 1/2 belt widths deflection at 70  fahrenheit. This is done to ensure that as the engine warms up that there is
enough room for the expansion of the sprockets.

It has been tested that as the sprocket warms from 70  to 150  that the sprockets can grow as much as .20 thou
on the diameter of the sprocket. This amount of growth on the upper sprocket changes the actual circumference by
over 1/16". Add this to the growth of the lower sprocket and the potential for breakage of the propeller shaft
(jackshaft) is very real. Therefore, it is advisable to follow a proper pre-flight and post-flight inspection of the drive
belt deflection.

ROTARY AIR FORCE THEREFORE HAS ESTABLISHED A TIME CHANGE ON THE PROPELLER SHAFT
(JACKSHAFT) OF 150 HOURS.

RAF 2000 owner have been notified on previous product notices that the propeller shaft (jackshaft) must also be
changed out if there is a propeller strike with some immovable object (breakage of any of the propeller blades).

The propeller shaft (jackshaft) must also be changed out if the upper sprocket runs loose on the shaft. To check if
your sprocket has been run loose grab the spacer between the upper sprocket and the bearing housing and try to
rotate this spacer while holding the propeller. If this spacer rotates the shaft and the spacer must be changed out.
Also the upper sprocket must be checked in a lathe to ensure that the propeller face and the face that the spacer
sits against are parallel to each other.

BUTLER TOOL & DESIGN INC., 641 S. NEWTON STREET, GOODLAND INDIANA 47948, TEL:219-297-4531
OR FAX:219-297-4554, CONTACT: JIM BUTLER, has a modification for the EA82 reduction drive assembly.
This company can be contacted directly if you would like your EA82 reduction drive modified.

*NOTE: AIRCRAFT PRODUCT NOTICE NO. 20 OUTLINES A TIME CHANGE COMPONENT.

*NOTE: THIS AIRCRAFT NOTICE AFFECTS ALL RAF 2000 GYROPLANES WITH THE EA82 SUBARU
ENGINE.

*NOTE: ADD THE INSPECTION OF THE PROPELLER SHAFT (JACKSHAFT) TO YOUR PRE-FLIGHT
AND POST-FLIGHT INSPECTIONS.

Issue Date: 1 November 1995 Revision Date: 17 Aug 2011 Revision No: 002

Page 1

ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD

PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
Web: www.rafsa.co.za Company Reg No: 2007/012378/07
Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-21
RAF 2000 GYROPLANE

NO. 21: HUB BAR

Mid 1996 RAF has improved the Hub Bar design.

Study the drawings below and determine which hub bar is installed on the rotor blades. The hub bar center section
that is 7/8" thick should be changed out at 150 hours of flight time.

Proper care and attention must be taken to inspect the hub bar for any nicks or deep scratches where stress can
accumulate. Any nicks or deep scratches must be sanded out so that stress will not accumulate at these points.

At 100 hours inspect the hub bar for any cracks with a 10 power magnifying glass at all the stress points and
radiuses.

Follow storage procedures as laid out in PRODUCT NOTICE NO. 19. Proper pre-flight and post-flight inspection of
the hub bar, gimble head, control systems, and control surfaces are a must to ensure safe flight.

*DRAWINGS OF CENTER SECTIONS INCLUDED

Issue Date: 10 October 1996 Revision Date: 17 Aug 2011 Revision No: 002
Page 1



ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD

PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
Web: www.rafsa.co.za Company Reg No: 2007/012378/07
Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-22
RAF 2000 GYROPLANE
NO. 22: FRONT WHEEL STEERING CHANGE UP

DRAWING ATTACHED.

*NOTE: THIS AIRCRAFT PRODUCT NO. 22: FRONT WHEEL STEERING CHANGE UP NOTICE
AFFECTS ALL SERIAL NUMBERS PRIOR TO AND INCLUDING SERIAL NO. H2-96-7-234.

Issue Date: 10 October 1996 Revision Date: 17 Aug 2011 Revision No: 002
Page 1



ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD

PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
Web: www.rafsa.co.za Company Reg No: 2007/012378/07
Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-23
RAF 2000 GYROPLANE

NO. 23: •1/4" and 3/8" MALE ROD ENDS - TIME CHANGE COMPONENT

•RUBBER MAST BUSHING PRE-FLIGHT - TIME CHANGE COMPONENT

•SERVICE - BELT DRIVE PRE-ROTATOR, inner cable, pulley c/w clutch disc

•GIMBLE HEAD CLEARANCE

•HUB BAR CLEARANCE

•1/4" and 3/8" MALE ROD ENDS - TIME CHANGE COMPONENT: Due to the failure of one rod end in the
CONTROL SYSTEM RAF has decided to put a time change factor of 250 HOURS on the 2 - 1/4" MALE ROD
ENDS, ARB 1/2" X 28.5" CONTROL TUBE ROD (1/2" aluminum round bar inside control tube), 8 - 3/8" MALE ROD
ENDS (2 at gimble head, 4 at split push tube scissor, and 2 at lower push tube arms) that are part of the control
system. Also continue with pre and post flight inspections as well as the inspections as laid out in the maintenance
schedule.

•RUBBER MAST BUSHING PRE-FLIGHT - TIME CHANGE COMPONENT: The rubber mast bushing is a time
change component and is to be checked during the pre-flight. A visual aid is to mark the 4" X 20" plastic with a pen
mark so that you can visually see if the mast has moved back from the standard position. If the position changes
the rubber mast bushing has broken through or deteriorated and must be replaced. However, this does not
remove your responsibility to remove the bolt and check the rubber mast bushing before every flight as part of the
pre-flight.

•SERVICE BELT DRIVE PRE-ROTATOR inner cable, pulley c/w clutch disc: The belt drive pre-rotator inner
cable requires regular maintenance to maintain a long life. Remove the inner cable and turn 180 (end for end), re-
grease, and re-install. The grease must be a high pressure, heavy duty grease the stringiest that can be found. If
the grease is to thin or light weight the inner cable will wind it out the top of the pre-rotator cable and cause
premature failure of the pre-rotator inner cable.

The pre-rotator clutch disc may come un-bonded and have to be serviced. Return to factory for replacement clutch
material. RAF recommends that you keep a spare 800-025-S15 pre-rotator pulley c/w clutch disc and 6008 DU
Bearing. To check the pre-rotator clutch unit remove the belt. The 6008 DU bearing should be checked on a
regular basis check for smoothness there should be no rough spots, looseness, or side play. The steel pressure
plate should also be removed on a regular basis and the glazing removed with a grinder and re-installed.

A plastic pre-rotator cable guide bracket is now available to replace the spring that held the pre-rotator outer cable
from rubbing or interfering with the push tubes. This bracket eliminates the sharp turn and keeps the outer cable
more in line at the gimble head and the pre-rotator clutch unit. Order 800-030-S20 (includes hardware) for $50
USD + SHIPPING.

Issue Date: 16 June 1997 Revision Date: 17 Aug 2011 Revision No: 002

Page 1

ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD

PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
Web: www.rafsa.co.za Company Reg No: 2007/012378/07
Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-23
RAF 2000 GYROPLANE

The size of the pre-rotator pull cable has been increased from 1/16" to 2 MM it is recommended that owners
change up to this size of cable. 132" @ .08" = $10 USD + SHIPPING.

•GIMBLE HEAD CLEARANCE RE: UPDATE PRODUCT NOTICE REF:C/PRONOT.RAF-6. Owners should
ensure that proper movement of the Gimble Head is maintained. Use the WARP DRIVE propeller protractor to
check the LATERAL MOVEMENT LEFT from center should be a full 10 - 12. LATERAL MOVEMENT RIGHT
from center should be a full 10 - 12. FORE MOVEMENT should be -1 or -2. AFT MOVEMENT should be a full
18 - 20. This LATERAL, and FORE and AFT movement should ensure proper control in flight. REMINDER the
3206 bearing should be changed at 200 HOURS as per the maintenance schedule.

•HUB BAR CLEARANCE to the teeter plate clearance must be NO MORE than 10 forward and NO MORE than
10 aft for a total of 20. After the Hub Bar has been installed pull one end of the Hub Bar against the stop and
rotate one full turn to ensure that the Hub Bar does not contact any gimble head components (example pre-rotator
bendix). ROTOR BLADE TRACKING BARS (for setting the pitch in the Rotor Blades) are also available from RAF
or ask for the drawings.

*NOTE: AIRCRAFT PRODUCT NOTICE NO. 23 OUTLINES TIME CHANGE COMPONENTS and
SERVICE.

Issue Date: 16 June 1997 Revision Date: 17 Aug 2011 Revision No: 002
Page 2

ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD

PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
Web: www.rafsa.co.za Company Reg No: 2007/012378/07
Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-23 + 24 COVER LETTER
RAF 2000 GYROPLANE

DEAR RAF 2000 GYROPLANE OWNER:

Please find enclosed:

1. PRODUCT NOTICE NO. 23. and PRODUCT NOTICE NO. 24 cover a number of different IMPORTANT
items. Read this information carefully and implement the items that apply to your RAF 2000 gyroplane.
Store this information in the Product Notice section of the Construction Manual.

2. BONUS OFFER outlines RAF's hours of operation as well as the BONUS BUCKS PROGRAM. Get your
project published in any newspapers or magazines and receive a CREDIT on your ACCOUNT. The credit
value will be up to the SOLE DISCRETION of RAF. *NOTE: The Factory Shut down is scheduled for
December 23, 1997 - January 5th, 1998.

3. POST CARD is to let you know which air shows the factory will be attending. Keep it handy. RAF would
love to see you there. The Post Card also INFORMS you about the ROTORCRAFT SAFETY
SYMPOSIUM and the ORGANIZATIONAL MEETINGS for the ASK FIRST SOCIETY. RAF is the
CORPORATE SPONSOR for the ASK FIRST SOCIETY organization.

RAF has always been a strong advocate of safety by training. Over the last number of years RAF has
been involved to unite the Owners, Certified Flight Instructors, and the Federal Bodies who write the laws
pertaining to the rotorcraft industry. If at all possible plan to attend October 17th -20th, 1997 to add your
voice to the growing number of rotorcraft/gyroplane enthusiasts who are concerned about safety by
training.

5. REMINDER SAFETY BY TRAINING. Here are 2 good reasons for getting training to ensure that you are a
competent pilot in command and signed off to SOLO by your Certified Flight Instructor: 1st your life, and
2nd your investment.

6. CUSTOMERS ONLY. You can purchase an updated copy of the EJ22 CONSTRUCTION MANUAL, which
includes construction hints, aircraft construction, Rotor Blade, and Hang Test, an EJ22 Engine Manual, all
Product Notices issued to date, Flight Manual Operating Limitations and Maintenance Schedule, plus 5
construction videos for $150 + shipping. Or various parts thereof at a nominal fee + shipping.

7. SPECIAL PRICING. Available to customers who want to update their RAF 2000 Gyroplane with the new
style (introduced in 1995) cabin enclosure, or the 130 HP EJ22 Legacy Subaru Engine, parts, and
components. Call the factory for details. Pricing laid out in enclosed flyer. Special pricing discounts will
apply.

Issue Date: 16 June 1997 Revision Date: 17 Aug 2011 Revision No: 002
Page 1

ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD

PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
Web: www.rafsa.co.za Company Reg No: 2007/012378/07
Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-24
RAF 2000 GYROPLANE

NO. 24: •EJ22 HTD BELT - TIME CHANGE COMPONENT
•SERVICE - BEARING EJ22 LOWER SPROCKET
•EJ22 SUBARU ENGINE BLOW-BY
•EJ22 SUBARU ENGINE FUEL

•EJ22 HTD BELT - TIME CHANGE COMPONENT: RAF 2000 owners and CFI's have been reporting varying life
spans for the HTD belt from 160 - 350 hours RAF believes there are circumstances such as belt tension that will
affect the life of the belt. Therefore, a time change factor of 100 HOURS on the HTD belt is recommended. Also
continue with pre and post flight inspections for unusual wear as well as the inspections as laid out in the
maintenance schedule.

•SERVICE - BEARING EJ22 LOWER SPROCKET: If your lower sprocket bearing contains 1 - R12RRU bearing it
must be checked to ensure that it is NOT LOOSE. If it IS LOOSE your lower sprocket may be sent back to the
factory for a CHANGE UP to the double bearing configuration. The cost will be approximately $45 CND plus
shipping, and brokerage.

However, this work can probably be done locally. Replace the R12RRU bearing with 2 - R12RR bearings and
either order the factory snout or have a machinist make one for you as per the following drawing.

•EJ22 SUBARU ENGINE BLOW-BY: It has come to our attention that as more hours are put onto the EJ22
Subaru Engines blow-by is increasing in the crank case. RAF has noticed a light film of oil in the air box.

RAF recommends that the PCV system that is run from the valve cover to valve cover with a "T" in the middle and
then a hose to the air box be removed. In its place a small 90 hose should be placed on each valve cover. This
will vent the crank case vapours to the atmosphere. As per the following drawing.

*NOTE: The EJ22 SUBARU ENGINE BLOW-BY repair will apply to all EJ22 SUBARU Engines
received by RAF 2000 Gyroplane owners prior to June 1997.

•EJ22 SUBARU ENGINE FUEL: As per the OPERATING LIMITATIONS MANUAL the recommended fuel for this
engine is premium auto fuel 92-93 octane. The EJ22 ENGINE was not designed to use leaded fuel.

Owners choosing to use 100 low lead do so at their OWN RISK.

Owners using 100 low lead should have mixture control devices installed on the aircraft as well as having an
Exhaust Gas Temperature Gauge to monitor cylinder number 3 and cylinder number 4.

Issue Date: 16 June 1997 Revision Date: 17 Aug 2011 Revision No: 002

Page 1

ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD

PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
Web: www.rafsa.co.za Company Reg No: 2007/012378/07
Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-24
RAF 2000 GYROPLANE

*NOTE: AIRCRAFT PRODUCT NOTICE NO. 24 OUTLINES SERVICE for the EJ22 SUBARU ENGINE
and components.

Issue Date: 16 June 1997 Revision Date: 17 Aug 2011 Revision No: 002
Page 2

ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD

PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
Web: www.rafsa.co.za Company Reg No: 2007/012378/07
Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-24
RAF 2000 GYROPLANE
NO. 24: •EJ22 SUBARU ENGINE BLOWBY

Issue Date: 16 June 1997 Revision Date: 17 Aug 2011 Revision No: 002
Page 3

ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD

PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
Web: www.rafsa.co.za Company Reg No: 2007/012378/07
Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-24
RAF 2000 GYROPLANE
NO. 24: •SERVICE - BEARING EJ22 LOWER SPROCKET

Issue Date: 16 June 1997 Revision Date: 17 Aug 2011 Revision No: 002
Page 4





ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD

PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
Web: www.rafsa.co.za Company Reg No: 2007/012378/07
Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-25
RAF 2000 GYROPLANE

NO. 25: •RUBBER MAST BUSHING - MANDATORY COMPONENT CHANGE
•1/16" AIRCRAFT CABLE - SERVICE BULLETIN

All RUBBER MAST BUSHINGS (BLACK material) must be replaced with the current production of RUBBER MAST
BUSHING.

The current production of RUBBER MAST BUSHING is a YELLOWISH translucent material.

Once this PRODUCT NOTICE NO. 25 has been complied with, customers are to continue with pre-flight visual
checks and periodic inspections of the RUBBER MAST BUSHING.

VISUAL CHECK: MARK the 4" X 20" plastic with a pen mark so that you can visually see if the CHEEK PLATES
have moved back from their standard position. If the CHEEK PLATE position changes, the rubber mast bushing
has broken through or deteriorated and MUST be replaced.

As per the following, RAF is also making available (to RAF 2000 CUSTOMERS ONLY) a better quality BERRY
MOUNT for the engine at a one time only REDUCED change-up price. Offer expires NOVEMBER 30, 1997.

The cost in USD will be as follows ONLY ONE per customer:

1 - RUBBER MAST BUSHING NO CHARGE
7 - BERRY MOUNTS (ENGINE MOUNTS) 40.00

Customers will be responsible for the shipping charges.

*NOTE: RAF 2000 Gyroplane kits shipped JULY 1997 have the current production of Rubber Mast
Bushing and Berry Mounts.

•1/16" AIRCRAFT CABLE - SERVICE BULLETIN

It has come to our attention that the 1/16" aviation cable used in the ADJUSTABLE PITCH and ROLL TRIM
SYSTEM and the ROTOR BRAKE SYSTEM, dependant on storage, use, and humidity in your area, CAN rust,
fatigue, and break as moisture gets trapped in the cable sheath.

Issue Date: 10 September 1997 Revision Date: 17 Aug 2011 Revision No: 002
Page 1

ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD

PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
Web: www.rafsa.co.za Company Reg No: 2007/012378/07
Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-25
RAF 2000 GYROPLANE

The factory recommends that customers, dependant on storage, use, and humidity in your area, REPLACE this
1/16" aircraft cable every 1 - 3 years. To prolong the life of the 1/16" aircraft cable spray a good quality penetrating
oil down the cable sheath every 25 hours also . Or INSTALL 1/16" stainless steel cable.

*NOTE: AIRCRAFT PRODUCT NOTICE NO. 25 OUTLINES •RUBBER MAST BUSHING-MANDATORY
CHANGE and PRE-FLIGHT INFORMATION and •1/16" AIRCRAFT CABLE-SERVICE
BULLETIN.

Issue Date: 10 September 1997 Revision Date: 17 Aug 2011 Revision No: 002
Page 2

ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD

PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
Web: www.rafsa.co.za Company Reg No: 2007/012378/07
Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-26
RAF 2000 GYROPLANE

NO. 26: •PRE-ROTATOR OUTER CABLE SHEATH - COLD -20C, or -10F WEATHER WARNING

In cold weather operation, it has been found that the PRE-ROTATOR OUTER CABLE SHEATH will continue to
harden as the temperature decreases.

RAF has determined that there will be a restriction of the aft movement of the controls when the temperature
reaches -20 Celsius or -10 Fahrenheit.

*NOTE: AIRCRAFT PRODUCT NOTICE NO. 26 OUTLINES: •PRE-ROTATOR OUTER CABLE SHEATH
-COLD -20C or -10F WEATHER WARNING and applies to all RAF 2000 Gyroplanes using
the Belt Drive Pre-rotator system.

Issue Date: 9 March 1998 Revision Date: 17 Aug 2011 Revision No: 002
Page 1

ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD

PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
Web: www.rafsa.co.za Company Reg No: 2007/012378/07
Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-27
RAF 2000 GYROPLANE

NO. 27: TEETER TOWER CHANGE UP; CRANK TRIGGER IGNITION, (CTI); PRE-ROTATOR BENDIX
HOUSING; TIP WEIGHTED ROTOR BLADES; ARE YOU READY TO SOLO?

TEETER TOWER CHANGE-UP in 1998 RAF conducted many test flights and monitored the vibration levels from
the rotor blade system. There were several items found that could be changed in order to provide a much
smoother flight.
1. A bridge was manufactured for the teeter towers to give a more solid box configuration to eliminate any

movement which may occur in the free standing teeter towers. The inventory code for the TEETER
TOWER CHANGE-UP is CU-310 the cost is $258 USD.
2. The apex of lift was increased with a taller cord block allowing for more coning without the vibration. The
inventory code for the HUB BAR CHANGE-UP for the taller towers is CU-501 the cost is $108 USD.
3. The entire cord screw was threaded to reduce any movement between the cord screw and the cord block
also allowing for quicker adjustments.
4. RAF started shipping the new style gimble head with the RAF 2000 GYROPLANE KITS in July 1998 the
new inventory code for the GIMBLE HEAD is 310-060-A01.

CRANK TRIGGER IGNITION (CTI) RAF has been working on this system for quite some time in the hopes of
eliminating the distributor and liquid filled coils. RAF has now successfully completed our test period and have
implemented this change in all production aircraft. The CTI has no moving parts and the coils are solid state so no
oil bath. RAF feels that this will give the RAF 2000 owners much better service than the system. RAF started
shipping the CTI in July 1998 the inventory code for the CTI CHANGE-UP is CU-720 the cost is $483 USD. A
VIDEO is available for the teeter tower, hub bar, and CTI Change-up the cost is $15 USD for the NTSC version and
$20 USD for the pal version.

PRE-ROTATOR BENDIX HOUSING the round outer housing for the pre-rotator bendix housing and the bearing
retainer have been updated by actually cutting an inside thread on the housing and outside thread on the bearing
insert. If your system is punch marked this should be safety wired until parts are replaced with the above improved
parts.

TIP WEIGHTED ROTOR BLADES are now available. RAF conducted flight tests on tip weighted rotor blades with
the results showing a more consistent rotor blade RPM and a prolonged increase in rotor blade RPM on landing. If
you are not sure if your RAF 2000 Gyroplane has tip weighted rotor blades check the rotor blades Serial Number it
will have a number plus 3 letters (one being a T). Previous rotor blade Serial Numbers had a number plus 2 letters.

ARE YOU READY TO SOLO? It appears that some of our RAF 2000 Gyroplane owners think they can do without

Issue Date: 16 December 1998 Revision Date: 17 Aug 2011 Revision No: 002

Page 1

ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD

PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
Web: www.rafsa.co.za Company Reg No: 2007/012378/07
Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-27
RAF 2000 GYROPLANE

flight training or minimal flight training. The result is many of our RAF 2000 Gyroplane owners are having to replace
parts. If you have suffered a rotor blade strike, RAF does not need to remind you a set of rotor blades cost $2,500
USD the gimble head is $1,000 USD so the minimum cost to repair and or replace parts is at least $3,500 USD
most roll over repairs cost between $4,000 - $6,000 USD. There is no substitute for proper flight training for your
own safety.

DO NOT RUSH to your solo flight. Only when you are signed off by a CERTIFIED FLIGHT INSTRUCTOR will
you be allowed to solo your aircraft. This will happen when you and your instructor feel that you are ready for your
solo flight. The RAF 2000 GYROPLANE is a technical aircraft that needs to be respected. Remember to fly to your
own capabilities not to the full flight envelope of the RAF 2000 Gyroplane.

RAF reminds you that even though the RAF 2000 GYROPLANE does fly well in wind this should be attempted only
by experienced pilots and even then high speed abrupt manoeuvres are not recommended when flying in high
winds, severe up and down drafts. Flight manoeuvres close to the ground may be DANGEROUS and CAUTION is
ADVISED. Many aviation companies consider a pilot "experienced" when the pilot has accumulated 1,000 hours
as pilot in command. RAF encourages you to be patient with your learning curve, give yourself time to learn, and
always FLY SAFE.

*NOTE: AIRCRAFT PRODUCT NOTICE NO. 27 TEETER TOWER CHANGE UP; CRANK TRIGGER
IGNITION, (CTI); PRE-ROTATOR BENDIX HOUSING pre-flight; TIP WEIGHTED ROTOR
BLADES. The above products were available after JULY 98 and STANDARD after AUGUST
98 for KIT SHIPMENTS. ARE YOU READY TO SOLO?

Issue Date: 16 December 1998 Revision Date: 17 Aug 2011 Revision No: 002
Page 2