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Builders Page for the Zenith XL

Following are the latest STOL CH 601 photo assembly guides. The following is published to supplement (and not replace) the drawings. If a discrepancy arises between these photo assembly guides and the Drawings, the Drawings always take precedence. These documents are presented in the Adobe Acrobat file format for online viewing and easy printing. The photos are presented in low-resolution for quicker downloads.

NOTICE: These documents contain copyrighted information and are NOT FOR DUPLICATION OR DISTRIBUTION.

DocumentsDescriptionRevisionLast Update
Inspection of the Main Gear Spring Attachment Points  5/2018
Fuel System Inspection  1/2018
Horizontal Stabilizer – Inspection Mandatory  1/2017
CorrosionWing strut and general corrosion inspectionlubrication and general aircraft maintenance1/2016
LinkSensenich Prop Service Bulletin 2014-02-04. Discontinue use of Jabiru composite propeller blades on UL Power Engines2/4/142014-02-04
LinkWhirlwind Prop Service Letter SL-GA-J2B-012714 BLADE CLAMP BOLT CRACK: All WhirlWind GA-J2B propellers with hubs in the Serial Number range 1000 to 1107 installed on UL Power engines 1/27/14
LinkRudder Pedals Safety Alert: Check rudder pedals for the correct material thickness (serial numbers 65-8563 to 65-8950) 9/26/13
Web LinkThe FAA has re-evaluated the CH601XL kit with the upgrade package (6-ZU) and determined that it meets the major portion requirements (51% rule). Note: When registering your aircraft with the FAA use the model name as it appears on the FAA listing of aircraft kits (“Zodiac CH 601 XL”) and the drawings. Do not add the “B” to the name when registering it with the FAA as this will not match the FAA information on file. 1/20/11
LinkNovember 72009: FAA Issues Special Airworthiness Information Bulletin: Zodiac CH 601 XL and CH 650  
DocumentRotax 912 Bed Mount Steel Bracket E1-1X: Check for cracks 6/2010
DocumentAndair Fuel Selector Service Alert 6/2010
Web LinkRequest your “B” model decals to display on upgraded Zodiac CH 601 XL and CH 650.More Info6/2010
View Video Clip 2/2010
Video ClipAero-TV video clip: Zenair’s Mathieu Heintz discusses the Zodiac CH601XL upgrade package… (from the Sebring LSA show in 1/2010). 5/2010
6-ZUZodiac CH 601 XL / CH650 Upgrade Package Drawings (revision 1/25/2010) 1/25/2010
Zodiac CH 601 XL / CH650 Upgrade Package Drawings
DocumentsDescriptionRevisionLast Update
revision 1/25/2010   
6-ZU-1BSupplemental drawing for earlier Zodiac XL models with 4 noseribs inboard of the fuel tank 2/12/2010
6-ZU-1Photo Assembly Guide: CH 601 XL / CH650 Upgrade Package: Section 6-ZU-1 Wing Spar & Rear Channel (Rev. 1.1) 2/16/2010
6-ZU-2Photo Assembly Guide: CH 601 XL / CH650 Upgrade Package: Section 6-ZU-2 Center Spar Section 12/17/2009
6-ZU-3aPhoto Assembly Guide: CH 601 XL / CH650 Upgrade Package: Section 6-ZU-3a Bellcrank Channel & Doublers 12/17/2009
6-ZU-3bPhoto Assembly Guide: CH 601 XL / CH650 Upgrade Package: Section 6-ZU-3b Bellcrank Channel & Doublers (fuselage) 12/18/2009
6-ZU-4Photo Assembly Guide: CH 601 XL / CH650 Upgrade Package: Section 6-ZU-4Aileron Control Stops Servo L Angles1/26/2010
doc369Zodiac CH 650 Structural Test to ASTM-SLSA  
ch-letter-7-09Letter from Chris Heintz: Recommendations for inspections and operating limitations 7/2009
pdf downloadFlutter analysis report: 27 pages 6/2009
newsletter172Chris Heintz update excerpted from the Zenair Newsletter Issue #172 (May-June 2009 issue) 6/2009
ZE-2008-01Zenair Europe issues a safety alert / service bulletin to Zodiac pilots and owners in response to the preliminary findings of an investigation into the fatal accident involving a Czech Aircraft Works Zodiac CH 601XL in the Netherlands. Note that this bulletin does not provide new information regarding the aircraft; it requests verification of what should already be in placenamelyproper tension of the control cables.
LinkPhoto guide: How to check the control cable tension of your Zodiac  
newsletterExcerpts from the Zenair Newsletter Issue #165  
Link601 Paper By William Wynne 6/1/2008
xl-parts-catZodiac XL Illustrated Parts Catalog. This new draft Parts Catalog makes it easy to identify parts of the Zodiac XL airframe (and to use with the new online parts ordering system).  
CH650 Parts Catalog 4/2007
601XL nose wheel forkZODIAC XL Nosewheel Fork Doubler 12/17/2004
Other Information
LinkCH650 Canopy Latch
Service ManualZodiac XL – S-LSA (factory-built with Continental O-200) Service (Maintenance) Manual
SLSA POHZodiac XL – S-LSA (factory-built with Continental O-200) Pilot Operating Handbook (POH)
newplane.comAdditional resources for owners and operators of the Zodiac S-LSA (factory-built with Continental O-200).
Flight-testFlight-test Zodiac XL – S-LSA (factory-built with Continental O-200) Flight Test Worksheet 7 pages
ground-testZodiac XL – S-LSA (factory-built with Continental O-200) Ground Test Checklist 5 pages
Pre-deliveryZodiac XL – S-LSA (factory-built with Continental O-200) Pre-Delivery Checklist 4 pages
VCI-373Cortec 373 Corrosion Protection brochure
LinkMaterial Safety Data Sheet – 10/2003
pneu-riveterUsing the pneumatic rivet puller – 12/18/01
w&bWeight & Balance Worksheet (2 pages) – 1/11
601xl-pohSample Pilot Operating Handbook for the ZODIAC XL (older manual from Europe) – 10/03
LinkNosewheel Bungee Installation Tool. This tool allows you to install or replace nose gear bungee easily in minutes.
LP Aero Plasticsonline documentation on handlingdrillingtrimming and cleaning acrylic canopy.

This web site is published strictly for informational purposes. It is maintained to provide a forum for exchanging information about Zenair designs. Any pictures, diagrams, drawings or graphs, are used for general identification only, and are not to be taken to represent technical drawings or replicas of exact parts. You should not consider the educational material in the web site to be the practice of general aviation.

This site is not intended to replace, substitute for or supersede any technical information contained in the drawings, any Federal Aviation Administration regulations, or the manufacturer’s manuals.

Neither Zenith Aircraft Company (ZAC) nor the authors guarantee the accuracy or completeness of any information published herein and neither ZAC or any other authors shall be responsible for any errors, omissions, or damages arising out of use of this information. This site is offered with the understanding that ZAC and any other authors are supplying information but are not attempting to render engineering or other professional services. If such services are required, the assistance of an appropriate professional should be sought.

These statements are to be considered disclaimers of responsibility from anything published here.