# NTSB ERA22LA241: Evektor-Aerotechnik Sportstar, N503RK, Lancaster, OH, May 21, 2022 - Type: NTSB accident investigation - Classification: Accident · No injuries · Class 3 · Limited · Final report - Date: May 21, 2022, 13:53 local (17:53 UTC) - Place: Lancaster, OH · A field near the airport - Coordinates: 39.70847, -82.60392 (estimated) - Nearby events: https://openairdocs.org/map.md?lat=39.7085&lon=-82.6039&mi=10 - Phase of flight: [Approach](https://openairdocs.org/ntsb-phases/500) (OpenAirDocs' grouping) - Defining event: [Approach-VFR pattern base: Loss of engine power (total)](https://openairdocs.org/ntsb-events/341) - Highest injury: No injuries - Injuries: 1 uninjured - Status: Completed - Report: Approved by Office Director - Investigation class: Class 3 - NTSB office: Eastern Region Aviation - Parties: FAA/FSDO, Rotech Flight Safety Inc. - NTSB case key (mKey): 105131 - NTSB case page: https://web.ntsb.gov/investigations/?ntsbnumber=ERA22LA241 - NTSB report (PDF, downloads): https://data.ntsb.gov/carol-repgen/api/Aviation/ReportMain/GenerateNewestReport/105131/pdf - Page: https://openairdocs.org/ntsb/ERA22LA241 ## Probable cause The improper installation and subsequent failure of the pushrod O-rings, which resulted in failure of the No. 4 connecting rod due to oil starvation. ## Findings NTSB's coded findings; those marked are part of the probable cause. - [Maintenance: replacement](https://openairdocs.org/ntsb-findings/02062020): Personnel issues › Task performance · Maintenance personnel (probable cause); cases with it: [Evektor-Aerotechnik SPORTSTAR, 1 case](https://openairdocs.org/ntsb-findings/02062020/cases.md?model=0600012), [All aircraft, 70 cases](https://openairdocs.org/ntsb-findings/02062020/cases.md) - [Engine (reciprocating): recip eng cyl section](https://openairdocs.org/ntsb-findings/01058530): Aircraft › Aircraft power plant · Incorrect service/maintenance (probable cause); cases with it: [Evektor-Aerotechnik SPORTSTAR, 1 case](https://openairdocs.org/ntsb-findings/01058530/cases.md?model=0600012), [All aircraft, 373 cases](https://openairdocs.org/ntsb-findings/01058530/cases.md) ## Sequence of events The events NTSB coded, in order, by phase of flight. The defining event best describes what happened. - [Prior to flight: Aircraft maintenance event](https://openairdocs.org/ntsb-events/040); cases with it: [Evektor-Aerotechnik SPORTSTAR, 1 case](https://openairdocs.org/ntsb-events/040/sequence.md?model=0600012), [All aircraft, 484 cases](https://openairdocs.org/ntsb-events/040/sequence.md) - [Initial climb: Loss of engine power (partial)](https://openairdocs.org/ntsb-events/342); cases with it: [Evektor-Aerotechnik SPORTSTAR, 2 cases](https://openairdocs.org/ntsb-events/342/sequence.md?model=0600012), [All aircraft, 1,858 cases](https://openairdocs.org/ntsb-events/342/sequence.md) - [Approach-VFR pattern base: Loss of engine power (total)](https://openairdocs.org/ntsb-events/341) (defining event); cases with it: [Evektor-Aerotechnik SPORTSTAR, 3 cases](https://openairdocs.org/ntsb-events/341/sequence.md?model=0600012), [All aircraft, 3,820 cases](https://openairdocs.org/ntsb-events/341/sequence.md) ## Analysis The pilot observed a reduction in engine power shortly after takeoff. While attempting to return to the airport, the engine lost power completely while on the downwind leg of the airport traffic pattern, after which the pilot performed an off-airport landing. The airplane’s fuselage and horizontal stabilizer were substantially damaged during the landing. Postaccident examination of the engine revealed that the pushrod O-rings had been incorrectly installed. This improper installation led to the disintegration of the O-rings, and the resulting debris to blocked the oil ports to the No. 4 connecting rod bearing. The lack of oil to the bearing resulted in the failure of the connecting rod, and the subsequent total loss of engine power. The airplane’s maintenance logbooks did not document any recent engine maintenance that would have required removing the engine’s cylinder heads. The cylinders were removed and reinstalled following repair nearly 9 years, and about 58 tachometer hours, before the accident. Based on available information, it is likely that the O-rings were improperly installed during this maintenance. ## Factual narrative On May 21, 2022, about 1353 eastern daylight time, an Evektor-Aerotechnik Sportstar Plus, N503RK, was substantially damaged when it was involved in an accident near Carroll, Ohio. The private pilot was not injured. The airplane was operated as a Title 14 Code of Federal Regulations Part 91 personal flight. The pilot reported that his airplane had been sitting for a few months for maintenance. He stated that after a thorough external inspection, he started the engine and let it run to ensure there were no anomalies. After all engine checks were completed, he taxied to the run-up area and prepared for takeoff. After takeoff, the pilot noticed that the engine was not developing full power. He leveled off to regain airspeed and reported the engine gained about 200 rpm. Ge turned north toward the practice area, but the engine once again started to lose power. He then turned back toward the traffic pattern for the runway. While on the downwind leg, the engine “quit,” and the pilot radioed “MAYDAY.” He made a forced landing in a field adjacent to the airport. During the landing flare, the airplane landed hard and the right main and nose landing gear collapsed. Postaccident inspection of the airplane by a Federal Aviation Administration inspector revealed the right horizontal stabilizer and fuselage were buckled. An examination of the engine revealed that when Nos. 1 through 3 cylinder heads were removed the pushrod O-rings were found installed incorrectly. The O-rings were crushed, partially disintegrated, and O-ring material was found in the bore of the crankcase. The No. 4 cylinder head was removed, and the intake pushrod tube O-ring was extruding from the bore. No breaches were found in the oil or cooling system. The crankshaft would not rotate by hand. The cylinder heads were subsequently removed. The No. 4 connecting rod was separated from the crankshaft. The No. 3 piston displayed scoring and liberated pieces of the pushrod O-rings were obstructing oil ports that fed the No. 4 connecting rod bearing. A review of the maintenance logbooks for the airplane did not reveal any recent engine maintenance that would require the removal of the cylinder heads. It was noted in the maintenance logbooks that the cylinders were removed and reinstalled for repair on August 4, 2013, at a tachometer time of 480 hours. This was 8 years and 10 months and 58.8 tachometer hours prior to the accident. ## Aircraft - Registration: [N503RK](https://openairdocs.org/deregistered/N503RK-2025-03-15), registration cancelled 2025-03-15, S/N 20050503, built 2006 (OpenAirDocs) - Reported make and model: EVEKTOR-AEROTECHNIK AS SPORTSTAR - Registry model: [Evektor-Aerotechnik SPORTSTAR](https://openairdocs.org/model/evektor-aerotechnik-sportstar) (registry code 0600012) (OpenAirDocs) - Registry engine: [Rotax 912ULS series](https://openairdocs.org/engine/rotax-912uls-series) (registry code 55572, 4 cycle) (OpenAirDocs) - Category: Airplane, amateur-built - Serial number: 20050503 - Year built: 2006 - Airframe hours: 539 - Engines: Rotax 912ULS 100 horsepower reciprocating - Damage: Substantial damage - Flight: Personal, Part 91 - Airworthiness certificate: Special, Experimental light sport (Special) - Last inspection: Condition, November 1, 2022, 20 hours before - Departed: LHQ, Lancaster, OH - Destination: Same as departure - Airport: LHQ, Fairfield County Airport - Equipment: Onboard weather, Stall warning system, ADS-B, Auto-pilot, Electronic flight bag or handheld device ## Flight crew As NTSB recorded them. NTSB leaves out names. - Pilot; age 51; injuries: none; private; airplane ratings: single-engine land; instrument ratings: airplane; medical: class 3, without waivers/limitations; last flight review May 4, 2022; seat: left; restraint: 4-point; flight hours: 240 total, 27 in this make and model, 163 as pilot in command, 2 in the last 90 days, 2 in the last 30 days, 2 in the last 24 hours ## Weather - Conditions: Visual (VMC), Day - Wind: 200° at 12 knots, gusting 19 - Visibility: 10 statute miles - Temperature: 86 °F, dew point 72 °F - Altimeter: 30.00 inHg - Observed at: KLHQ, 4 nm away - METAR: KLHQ 211853Z AUTO 20012G19KT 10SM FEW042 FEW055 30/22 A3000 RMK AO2 LTG DSNT W SLP148 T03000217 ## FAA reports on this event (1) The FAA's own accident and incident reports, matched to the aircraft by N-number and date (OpenAirDocs). - [Accident 20220521008999A](https://openairdocs.org/incident/20220521008999A), May 21, 2022: Evektor-Aerotechnik As SPORTSTAR, Lancaster, OH, Substantial damage. A private pilot [privacy data omitted], with no eis history was taking off out of Fairfield County Airport (lhq), runway 28, IN [privacy data omitted] an… From the NTSB's public API. Aircraft are matched to registry aircraft by N-number and event date, checked against the reported serial number, make and model; the registry's history has gaps, so older matches can be wrong. Compare the reported make and model. --- OpenAirDocs.org is an independent research project of [Contrail Labs](https://contraillabs.com/). It is not affiliated with the FAA or the NTSB. Source documents are U.S. government works in the public domain.