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The Freedom of Flight

Click here to submit a Defect Report on-line 

October 2017

 securite leaf

Parachutal phases were observed on a few manufactured “Leaf” while pulling “Ears” in non-accelerated flight mode.
The wing will come out of the parachutal phase as soon as the “Ears” are reopened.
Although we have not noticed it, this problem could also appear on high incidence phases, for example during winch towing take-offs.
After checking a few LEAF already manufactured, we found that some were actually set with a slow flying configuration and to the maximum allowed for certification approval tolerances, all sizes could be concerned.
To remedy the problem, we validated a new quicker setting for production on all new wings without modifying the certification characteristics.
For the LEAF owners with a serial number not ending with the letter "A", we have a line kit available to eliminates the risk of a parachutal phase.
The line replacement can be done by either contacting your local dealer, a certified repair center, or the SUPAIR Customer Service Department directly : This email address is being protected from spambots. You need JavaScript enabled to view it.
Note: This problem does not concern the LEAF-LIGHT.
Safety Note LEAF available here


May 2017

Rigging Cables with Roll Swaged End Terminals - Inspection / Replacement

All Microlights of the following types where P & M Aviation Ltd are the Type Approval Holder:
BM4 Gemini Flash
BMIO Pegasus Flash
BIVI14 Gemini Flash 2
BIVI16 Scorcher
BM17 Pegasus Flash 2
BM23 Gemini Flash 2 Alpha
BM43 Mainair Mercury
BM47 Mainair Blade
BM51 Mainair Blade 912
BM54 Mainair Rapier
BM60 Mainair Blade 912S
BM70 Quik GT450
BM77 QuikR
BM80 Quik GTR
BM81 PulsR
A P&M Quik GT450 in a flying school had a partial failure of a lower side rigging cable (Part No. YQD-045) when recovering from a spiral manoeuvre, within the limits of the flight envelope. These cables are arranged in pairs, to give a backup load path. The second cable carried the load and the aircraft landed safely.




Hang Bolt plus Lanyard - Inspection / Replacement

All Microlights of the following types where P & M Aviation Ltd are the Type Approval Holder:
BM44 Pegasus Quasar 2 TC
BM46 Pegasus Quantum 15
(Rotax 2-stroke engines)
BM50 Pegasus Quantum 15-912
BM56 Pegasus Quantum 15-HKS
BM66 Pegasus Quik
BM70 Quik GT450
BM77 QuikR
BM80 Quik GTR
BM81 PulsR
The lanyard on a hang bolt plus lanyard component was found to be under swaged which allowed it to detach at a low load. The lanyard is essential to stop the hang bolt pinch nut from slackening off. Should the pinch nut fall off there would not be anything to prevent the hang bolt from potentially migrating out of its housing and the wing would then detach. This problem was identified as a manufacturing deficiency of part number YQB-31302 and affected three batches of the component: A9835, A9868 and A9880.


JUNE 2016

Subject One:

Safety notice for Sup Air paraglider harnesses buckles.     CLICK HERE TO SEE THE FULL REPORT.


Subject Two:

Safety notice for paraglider harnesses equipped with Finsterwalder CLICK-LOCK
and T-LOCK buckles in the chest strap.


Click-Lockand T-Lock buckles

In the past three months, there have been two incidents involving older paraglider harnesses equipped with CLICK-LOCK buckles (HSi10) in the chest strap. The buckles had opened unintentionally during flight while they were under load. In one of the cases this happened during a SAT maneuver (spreading of the chest strap due to the pilot resting on the riser), in the other case the reason was presumably the load applied by the body weight of the pilot who was hanging only in the leg straps.

Finsterwalder has conducted a technical investigation and found the following:
The hooks of the metal tongue can wear out through the frequent diagonal load changes the chest strap is subject to. This might lead to decreased load capacity and – in the case of sufficiently high diagonal load transmission – the buckle might open unintentionally.
As a consequence of this finding, Finsterwalder has limited the respective buckles’ service time to 4 years if they are used in paraglider chest straps. The harness manufacturers have already been informed accordingly.

To date, there have been no unintentional openings of T-LOCK buckles. However, since their mechanism resembles that of CLICK-LOCK buckles, the problem is likely to be the same.

Finsterwalder calls on all owners of harnesses equipped with CLICK-LOCKs (HSi10) or T-LOCKs in the chest strap to determine their buckles’ previous usage time by checking the routine test date on the sample inspection label. If this date indicates a usage time of more than 4 years, the harness is not airworthy for now and may not be used for flying anymore. Affected owners should contact their harness manufacturer.

The service time limitation applies only to CLICK-LOCK and T-LOCK buckles that are used in paraglider chest straps. When used for applications where only static loads are involved, the CLICK-LOCK and T-LOCK buckles’ service life is 10 years.

The following harness manufacturers have used the mentioned buckles in one or more of their models: Advance, AVA Sport, APCO, Finsterwalder & Charly, KARPO FLY, SKY Paragliders, SkyTrekking, SOL, Woody Valley. Besides the buckles are used in paramotor harnesses of several manufacturers.

Finsterwalder GmbH
81247 München

The following ADVANCE products are fitted with these types of chest strap buckles:

• ADVANCE PRO 2+, Hsi68 T-LOCK (DHV GS-03-0273-03)


March 2016

Glass Fuel Filter Failure

Airborne XT-912 (2005) TSN 680hrs.

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

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

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

broken fitting   image002


Broken Wheel Spat Bracket

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

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

broken fitting   image002

Cracked RH Wing Adjuster Webbing Cap

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


September 2015

Hinge Batten Fitting Security - Airborne Windsports Wings

Identification: SB-019 (Click to follow link)

Status: Active

Issue Date: 01-09-2015

Issued By: Rick Duncan

Applicability: All Airborne Windsports Wings

Compliance: 100 Hourly line maintenance

Reference: Material Airborne Engineering Report 15/025/DS

Hinge Batten Fitting Security SB-019


August 2015

Malibu bottom upright fitting wire wear issue

Applies from: 17th August, 2015

Applies to: Any Moyes glider using round uprights.

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

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

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

broken fitting

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


The photo shows a broken fitting from a training glider.

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


January 2015

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

Aircraft Type: Airborne XT-582

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

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

If cracking is found, please contact Airborne directly.

Resolved: Airborne have increased the length of the bracket.

XT 582 Intake Silencer Bracket


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

Aircraft Type: Airborne XT-912B

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

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

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

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

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

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

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

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

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

EngMount 1EngMount 2

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

Aircraft Type: Airborne XT-912 Rotax 80hp

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

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

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

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

FuelShut off 1FuelShut off 2

June 2009

582 Oil Filter Bracket Failure

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


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

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

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

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


April 09

NZ CAA Notice Regarding findings on Airborne XTS 912 Microlight Materials

19 May 08

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

6 October 05

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


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A Paraglider pilot sits in a harness below a fabric wing that holds its shape through suspension lines and air pressure.
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