Robinson Helicopter Overhaul: The 2,200-Hour / 12-Year Guide

Every Robinson reaches a hard overhaul/inspection limit: 2,200 hours of flight time or 12 calendar years, whichever comes first (2,400 hours on the R44 Cadet, 2,000 on the R66). At that point the aircraft is grounded until either an overhaul or 12-year inspection occurs. APEX coordinates Robinson overhauls at both locations.

What triggers a Robinson overhaul?

Two limits run in parallel, and the first one reached governs. The hour limit is tracked on the Hobbs and the component cards; the calendar limit starts the day the aircraft is built. A low-time Robinson that has sat for twelve years still hits the limit, see the 12-year inspection for why. Robinson publishes the governing service life in its maintenance manuals and official publications.

What gets replaced at overhaul?

The overhaul is not just an inspection, it is a scheduled replacement of required components, parts and life-limited hardware, plus a powerplant decision. In broad terms the work covers:

• Main and tail rotor blades and hub components per the overhaul kit
• Drive system, belts, sheaves, bearings, clutch, and gearbox components
• Flex couplings, bearings, and life-limited hardware throughout the airframe
• Various required NDTs per RHC guidelines
• Engine, overhauled-exchange, rebuilt, or new
• Inspection, re-finish, and re-assembly to factory specification

The exact contents differ by model. See the kit pages for the R22 and R44.

How long does an APEX field overhaul take?

Plan on 4 to 9 months (depending on the aircraft condition and customer's needs) for a field overhaul once the kit and engine are in hand, and start the conversation early, because kit and engine lead times drive the schedule more than shop time does. Begin planning roughly 12 months before the limit.

How much does a Robinson overhaul cost?

Cost is dominated by the condition of the aircraft, total time, engine decision, AD and SB compliance and any options requested, i.e., interior, avionics upgrade, paint work, windshield replacement. Engine overhaul and kit pricing are the main drivers of cost, these prices change frequently, contact APEX for a current estimate.

Should you overhaul or sell?

Near the limit, the spread between “overhaul then sell” and “sell as a run-out” can decide tens of thousands of dollars, and sometimes trading up to a newer aircraft beats both. We run that math with you in the overhaul-or-sell guide. Ready to plan the work? Request an overhaul estimate, or talk to us about selling before overhaul.