Operation After Maintenance

FAR 91.407 — Operation After Maintenance

FAR 91.407 explains return-to-service requirements after maintenance, preventive maintenance, rebuilding, or alteration—including operational check flights.

In Plain English

FAR 91.407 sets the rules for flying an aircraft after it has had maintenance, preventive maintenance, rebuilding, or alteration. Before that aircraft can be operated again, two things must happen:

It must be approved for return to service by a person authorized under § 43.7 (typically an A&P mechanic, IA, or repair station, depending on the work).
The required maintenance record entry under § 43.9 or § 43.11 must be made in the logbooks.

If the work performed could have appreciably changed the aircraft's flight characteristics or substantially affected its operation in flight (think major alterations or major repairs), you can't carry passengers until:

An appropriately rated pilot holding at least a private pilot certificate flies an operational check flight, and
That flight is logged in the aircraft records.

The check flight isn't required if ground tests or inspections conclusively show the work didn't meaningfully change how the aircraft flies. Operationally, this protects you and your passengers from being the first to discover a rigging or installation problem after major work.

Regulation Text

14 CFR § 91.407

§ 91.407 Operation after maintenance, preventive maintenance, rebuilding, or alteration. (a) No person may operate any aircraft that has undergone maintenance, preventive maintenance, rebuilding, or alteration unless— (1) It has been approved for return to service by a person authorized under § 43.7 of this chapter; and (2) The maintenance record entry required by § 43.9 or § 43.11, as applicable, of this chapter has been made. (b) No person may carry any person (other than crewmembers) in an aircraft that has been maintained, rebuilt, or altered in a manner that may have appreciably changed its flight characteristics or substantially affected its operation in flight until an appropriately rated pilot with at least a private pilot certificate flies the aircraft, makes an operational check of the maintenance performed or alteration made, and logs the flight in the aircraft records. (c) The aircraft does not have to be flown as required by paragraph (b) of this section if, prior to flight, ground tests, inspection, or both show conclusively that the maintenance, preventive maintenance, rebuilding, or alteration has not appreciably changed the flight characteristics or substantially affected the flight operation of the aircraft. (Approved by the Office of Management and Budget under control number 2120-0005)

Oral Exam Questions a DPE Might Ask

Q1Before you fly an airplane that just came out of an annual inspection, what does FAR 91.407 require?

Per FAR 91.407, the aircraft must be approved for return to service by a person authorized under § 43.7, and the required maintenance record entry under § 43.9 or § 43.11 must be made before operation.

Q2If a major alteration was performed that could change the aircraft's flight characteristics, when can you carry passengers?

Under FAR 91.407(b), you can't carry passengers until an appropriately rated pilot with at least a private pilot certificate flies an operational check, confirms the aircraft operates properly, and logs the flight in the aircraft records.

Q3Is a check flight always required after major maintenance?

No. FAR 91.407(c) allows you to skip the check flight if ground tests, inspection, or both conclusively show the work did not appreciably change flight characteristics or substantially affect flight operation.

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Related Sections in Part 91

§ 91.1

Part 91 Applicability