Downloads
Installation Help
Installation Manual
Wiring Diagram
Fuel Flow Block Diagram
Bulkhead Fitting Drill Template For Use With NAVIFLOW
Installation Videos
VIDEO #1
Boost Pump Offering Overview
VIDEO #2
TSi Wing Mounting & Plumbing
VIDEO #3
Boost Pump Retrofit Harness
VIDEO #4
Preparing The Fuel Selector
VIDEO #5
Pump Testing and Configuration
VIDEO #6
Boost Pump Install Wrap Up
Testing Data
FPCM Software Updates
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Frequently Asked Questions
Fuel Boost System
No, the base system is useful for and can be used on all Rotax iS equipped low wing aircraft.
Yes, the mounting kit which is currently available for the Sling TSi is not required to install the system. Once you find a suitable pump location, you can create your own plumbing.
If you wish to take advantage of the automatic Rotax pump activation you will need to connect to the fuel pressure sensor.
Yes, there is a ground discrete that can be connected to an LED lamp on the panel or to an EFIS system that will give indication of an automatic Rotax Backup Pump activation.
In the unlikely event the system fails and you need the boost pumps, the boost pump override switch will turn both pumps on manually. If the system can’t detect which position the selector is in, it will force both pumps on. If power is lost to the FPCM, both pumps will default to on so long as they are still powered.
No, the pumps used are free flow diaphragm style pumps with a spring loaded check valve. Fuel will always flow even when the pump is off.
With both pumps on all the time, the flow of pump for the tank not selected will be blocked by the fuel valve. Though this is not ideal for pump life, there will be no negative effect on the fuel system otherwise.
There are several ways to turn off the system. The first is to pull the breaker. In the event of an emergency situation, if both fuel pump switches are turned off or the fuel valve is selected to off the system will turn both of the pumps off.
Naviflow
The Naviflow fuel manifold reduces the number of lines and connections needed forward of the firewall for a nice compact fuel delivery solution.
Naviflow can be used on any Rotax iS series engine.
No, many of the aircraft kits come with this sensor so we do not include it.
All of the Fuel Fittings are AN-6 and will come with the kit.
The check valve rubber hose is 5/16″ hose and will need to be replaced as part of Rotax’s 5-year rubber replacement. We can supply hose and clamps if needed.
There are 2 sizes of aluminum washers, M14 and M12, these washers need to replaced each time you remove the banjo bolts and can be purchsed from our online shop.
Be sure that the arrow on the check valve is in the same direction as flow, the back of the arrow should be toward the inlet side and the head of the arrow toward the outlet side.
A PTFE thread tape or sealer such as Permatex 80631 can be used. DO NOT use a thread sealer not made for gasoline, it will not hold up, and could cause clogs in the fuel system.
There a total of 6 M5 mounting screws, 3 for the manifold and 3 for the Gascalator, these need to be torqued to 50 in-lbs. Use blue 242 Loctite or equivalent to keep the screws in place.
The flow of fuel starts at the feed from the firewall or selector valve and goes to the inlet of the gascolator, from the outlet of gascolator to the inlet on the Rotax pump module, from the outlet of the Rotax pump module to the inlet of the fuel manifold, from the outlet of the fuel manifold to the fuel rail of the engine, from the fuel return on the engine to the manifold return tee, from the manifold return tee to the firewall or fuel selector return.
Fuel Lines
All Fuel Lines Are Made Of PTFE (Teflon) Type B. They are covered in a stainless steel braiding.
We use a high quality aluminum PTFE-specific fitting with a compression sleeve to securely seal the lines.
Yes, we can manufacture custom fuel lines for you. Please use the custom fuel lines product on our store.
The main advantage of using PTFE is service life of the line. Unless there is damage from accident or improper installation, these lines will last the life of the airplane. PTFE also will not permeate fuel vapor like rubber lines do which cuts down on fuel odors inside the cockpit. Lastly, there are no hose clamps which makes it easier to install and if installed correctly will not leak.
All of the fuel fittings are AN-6 and will come with the kit.
PTFE is rated for 500°F so it has good heat resistance, however all lines forward of the firewall will have black fire sleeve installed with the following temperature specs.
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Operating Temperatures:
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-65°F (-54°C) minimum continuous
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500°F (260°C) maximum continuous
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2,000°F (1,090°C) intermittent 15-20 minutes
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3,000°F (1,650°C) intermittent 15-30 seconds
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All lines are pressure tested before shipping, however, we will exchange any line that has a leak as long as there is not damage to the line or fitting.
AN fittings by design do not need any sealant.
| AN Size | Aluminum Fittings | |
|---|---|---|
| in.-lbs. | ft.-lbs. | |
| -02 | 50-80 | – |
| -03 | 70-105 | – |
| -04 | 100-140 | – |
| -05 | 130-180 | – |
| -06 | 150-195 | – |
| -08 | – | 22.5-29 |
| -10 | – | 30-36 |
| -12 | – | 38-46 |
| -16 | – | 58-70 |