Challenger Aircraft Maintenance
Flightstar provides FAA-certified Challenger aircraft maintenance for the 300/350/3500 and 604/605 series from our Part 145 Repair Station in Savoy, Illinois. Our factory-trained technicians support scheduled inspections, heavy maintenance events, and avionics troubleshooting for corporate and business aviation operators throughout the Midwest and nationwide.
Challenger 300 / 350 / 3500 Maintenance
Flightstar supports the Challenger 300 platforms with scheduled and unscheduled maintenance, advanced troubleshooting, and service bulletin compliance.
- Hourly, monthly, & heavy maintenance inspections
- Avionics inspections & troubleshooting
- Service bulletin incorporation
- Engine / APU inspection & line maintenance
- Structural & Corrosion inspections or repairs
- Hydraulic troubleshooting and functional checks
- Pre-Buy inspections
- Landing gear support
- Window replacement
- Battery servicing
- RVSM & ADS-B compliance
- Tire and wheel NDT
Challenger 604 & 605 Maintenance
Our teams provide comprehensive heavy maintenance support for the Challenger 604 and 605, including structural inspections, electrical troubleshooting, and cabin systems support.
- Hourly, monthly, & heavy maintenance inspections
- Service bulletin incorporation
- Structural & Corrosion inspections or repairs
- Hydraulic troubleshooting and functional checks
- Avionics inspections, troubleshooting, & upgrades
- Cabin Entertainment Systems
- RVSM & ADS-B compliance
- Weight & balance
- Engine & APU inspection
- Pressurization testing
- Window replacement
- Battery servicing
Bombardier-Trained Technicians & OEM Support
- Challenger Maintainers since 2009
- Relationship with OEM support channels
- Bombardier relationship since 2012
FAA Part 145 Repair Station
We hold a Class 1, 2, 3, and 4 FAA Repair Station Certificate with the FAA
Foreign approvals
Flightstar holds foreign approval from both EASA and Transport Canada, TCCA
Full Avionics Sales & Service
Representing industry leaders in the avionics world through sales and service
Level III NDT Capabilities
Our Non-Destructive Testing teams are trained and certified in all 5 NDT disciplines
Hangar Space
Flightstar has steadily grown to encompass over 137,000 square feet of hangar space and nearly 195,000 square feet of structures at Willard Airport, KCMI.
Challenger Maintenance in Savoy, Illinois — Serving the Midwest & Nationwide
Flightstar is located at University of Illinois–Willard Airport (KCMI) in Savoy, Illinois. Our central Midwest location allows us to efficiently support operators throughout Illinois, Indiana, Missouri, Iowa, and across the United States.
Whether you require scheduled inspections, unscheduled maintenance, or Aircraft-on-Ground (AOG) support, Flightstar delivers responsive service backed by decades of experience.
Let's Talk About Your Challenger Maintenance Needs
Rodd Caldwell
Technical Sales Director
Frequently Asked Questions
Do you perform heavy inspections on the Challenger 604?
Yes. Flightstar performs comprehensive heavy maintenance inspections for the Challenger 604 and 605 at our FAA Part 145 Repair Station in Illinois.
Do you support Challenger 300 and 350 inspections?
Yes. We provide calendar, hourly, and phase inspections.
Where is Flightstar located?
Flightstar is located at the University of Illinois–Willard Airport (KCMI) in Savoy, Illinois.
What types of operators does Flightstar support?
We support business and corporate aviation operators, charter providers, and aircraft owners.