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Maintenance Cost guide

Aircraft Maintenance Cost:
Planning for Expected
and the Unexpected

Maintenance is the most variable ownership cost and the one most often underestimated by new buyers. An enrolled maintenance program dramatically reduces financial surprices.

Reliability Metrics

Schedules vs Unscheduled Maintenance

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Scheduled Maintenance

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Calendar and cycle-based inspection and tasks
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Planned in advance and performed on schedule
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Predictable and budgetable
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Includes routine inspections, parts replacement and compliance tasks.
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Designed to keep your aircraft safe, reliable and compliant.

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Unscheduled Maintenance

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AOG events, component failures or system faults
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Caused by wear, damage or unforeseen events
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Unpredictable and often urgent
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Includes weather damage, bird strikes and unexpected repairs
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The biggest source of unplanned costs and downtime.

maintenance

Hourly Cost Programs

Honeywell

msp (engines)

Honeywell MSP is an hourly maintenance program designed to help operators manage eligible engine maintenance costs through predictable coverage and scheduled contributions. Program terms and coverage vary by engine and enrollment agreement.

best for:

Owners seeking structured coverage for eligible Honeywell-powered engines.

jssi

jssi (multi-component)

JSSI maintenance programs can provide structured coverage for selected aircraft components and maintenance expenses. Depending on the program, coverage may help owners plan for major maintenance events and reduce exposure to unexpected costs.

best for:

Owners seeking broader maintenance cost protection across multiple aircraft systems.

Bombardier

smart parts

Bombardier Smart Parts is designed to provide coverage for eligible aircraft components and replacement parts, helping owners manage certain maintenance expenses with more predictable cost planning.

best for:

Eligible Bombardier aircraft owners seeking component coverage.

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Benefits:

Cost predictability, priority service, global support and increased resale value.

Cost:

Adds to hourly operating cost but significantly reduces AOG exposure and large out-of-pocket expenses.

Expense Baselines

Annual Maintenance Cost Ranges

aircraft category

typical annual schedule maintenance*

recommended reserve for unscheduled**

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light jet

$75,000–$200,000
$50,000–$150,000
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midsize jet

$125,000–$300,000
$75,000–$200,000
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super midsize jet

$175,000–$450,000
$100,000–$300,000
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heavy jet

$250,000–$700,000
$150,000–$500,000
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ultra long range jet

$400,000–$1,000,000+
$250,000–$750,000+
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Major inspections (5-year, 10-year) can create significant spike costs. Plan ahead.

* Includes routine inspections, labour, and commonly scheduled maintenance items.
** Reserve recommendations vary based on aircraft age, utilization, maintenance history, enrolled programs, and upcoming major inspections.

Capital Allocations

Reserve Fund Planning

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Calculate Monthly Accrual

Set aside a monthly amount for expected future maintenance based on your aircraft's utilization, maintenance schedule, component status, and upcoming inspection requirements. Regular contributions can help spread major expenses across the ownership period.
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What to Reserve For

A maintenance reserve may include funds for major inspections, engine events, component replacements, unscheduled repairs, landing gear work, avionics upgrades, and other significant maintenance requirements.
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Why It Matters

Large maintenance events can occur infrequently but have a significant financial impact. A properly funded reserve helps owners manage these expenses without disrupting operational plans or requiring unexpected capital contributions.
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A well funded reserve = Peace of mind and operational readiness.

valuation

Maintenance & Resale

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Summary:

An aircraft's maintenance history can have a significant impact on its marketability and resale value. Complete records, compliance with scheduled maintenance requirements, participation in recognised maintenance programs, and timely resolution of discrepancies can all make an aircraft more attractive to prospective buyers.

When preparing an aircraft for sale or evaluating a purchase, maintenance status should be reviewed alongside airframe and engine times, upcoming inspections, component life limits, and deferred maintenance items. A well-maintained aircraft with complete documentation may be easier to market and support a stronger valuation.
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Calculate Your Total Ownership Costs

Estimate the annual cost of owning and operating a private aircraft based on your aircraft category, expected flight hours, mission profile, and major fixed and variable expenses. Use the Ownership Cost Calculator to explore how maintenance, fuel, crew, insurance, hangar, and other costs contribute to your total ownership budget.

Ownership Cost Calculator
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100% Confidential. No obligation.