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Rotax MMH-912 Series Maintenance Manual

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MAINTENANCE MANUAL

FOR ROTAX® ENGINE TYPES

(HEAVY MAINTENANCE)

Ref. No.: MMH-912

MMH-914

picture 914 UL 3 DCDI with options

picture 912 ULS 3 DCDI with options

ROTAX ® 912 AND 914 SERIES

part no.: 899603

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Summary of Contents for Rotax MMH-912 Series

Page 1 �� MAINTENANCE MANUAL FOR ROTAX® ENGINE TYPES (HEAVY MAINTENANCE) Ref. No.: MMH-912 MMH-914 picture 914 UL 3 DCDI with options picture 912 ULS 3 DCDI with options ROTAX ® 912 AND 914 SERIES part no.: 899603...
Page 2 This legend shall be included on any reproduction of these data, in whole or in part. Copyright 2009 © - all rights reserved. ROTAX is a trade mark of BRP-Powertrain GmbH & Co KG. In the following document ®...
Page 3: Table Of Contents
BRP-Rotax Maintenance Manual SECTION 00 INTRODUCTION 1) Table of contents SECTION 00 INTRODUCTION 1) Table of contents ..................00-00-00 / 3 2) List of chapters ..................00-00-00 / 5 3) Index ....................... 00-00-00 / 7 4) List of the valid pages ................00-00-00 / 11 5) Table of amendments ................
Page 4 BRP-Rotax Maintenance Manual NOTES 00-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 4 May 01/2007...
Page 5: List Of Chapters
BRP-Rotax Maintenance Manual 2) List of chapters INTRODUCTION ..........00 POWER PLANT ..........71 ENGINE ............72 FUEL SYSTEM ..........73 IGNITION SYSTEM .......... 74 COOLING SYSTEM .......... 75 ENGINE CONTROL .......... 76 EXHAUST SYSTEM AND TURBOCHARGER .. 78 LUBRICATION SYSTEM ........79 ELECTRIC STARTER ........
Page 6 BRP-Rotax Maintenance Manual NOTES 00-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 6 May 01/2007...
Page 7: Index
BRP-Powertrain Maintenance Manual 3) Index Electric starter 80-00-00 / 3 Airbox temperature 76-00-00 / 9 Electric starter installation 80-00-00 / 12 Alternators 74-00-00 / 3 Electric starter dismantling 80-00-00 / 5 Auxiliary tools 00-00-00 / 37 Electric starter inspection 80-00-00 / 9 Electric starter diassembly 80-00-00 / 11 Boost pressure display 73-00-00 / 16 Electronic module 74-00-00 / 14...
Page 8: Edition 1 / Rev
BRP-Powertrain Maintenance Manual Ignition electric set fitting 74-00-00 / 43 Ignition electric set removal 74-00-00 / 35 PC interface 76-00-00 / 12 Ignition housing 72-00-00 / 14 Piston rings inspection 72-00-00 / 79 Ignition housing inspection 72-00-00 / 11 Pistons fitting 72-00-00 / 86 Ignition housing removal 72-00-00 / 11 Pistons inspection 72-00-00 / 77 Ignition timing 74-00-00 / 19...
Page 9 BRP-Powertrain Maintenance Manual Table of amendments 00-00-00 / 19 Target pressure reduction 76-00-00 / 8 TCU inspection 76-00-00 / 32 Technical data 71-00-00 / 11, 71-00-00 / 15 Temperature measuring system 71-00-00 / 22, 75- 00-00 / 15, 79-00-00 / 26 Three-way solenoid valve 76-00-00 / 53 Throttle potentiometer calibration 76-00-00 / 31 Throttle potentiometer inspection 76-00-00 / 37...
Page 10: Edition 1 / Rev
BRP-Rotax Maintenance Manual NOTES 00-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 10 May 01/2007...
Page 11: List Of The Valid Pages
BRP-Powertrain Maintenance Manual 4) List of the valid pages 02708 Chapter Page Chapter Page Date Date 43 10 01 2010 Cover page 44 10 01 2010 00-00-00 1 05 01 2007 45 10 01 2010 2 05 01 2007 46 10 01 2010 3 05 01 2007 47 10 01 2010 4 05 01 2007...
Page 12 BRP-Powertrain Maintenance Manual Chapter Page Chapter Page Date Date 57 07 01 2008 16 07 01 2008 58 10 01 2010 17 05 01 2007 59 10 01 2010 18 10 01 2010 60 05 01 2007 19 10 01 2010 61 07 01 2008 20 10 01 2007 62 05 01 2007...
Page 13 BRP-Powertrain Maintenance Manual Chapter Page Chapter Page Date Date 100 05 01 2007 25 07 01 2008 101 05 01 2007 26 07 01 2008 102 07 01 2008 27 10 01 2010 103 05 01 2007 28 07 01 2008 104 05 01 2007 29 10 01 2010 105 05 01 2007...
Page 14 BRP-Powertrain Maintenance Manual Chapter Page Chapter Page Date Date 51 05 01 2007 8 05 01 2007 52 05 01 2007 9 05 01 2007 10 05 01 2007 53 05 01 2007 11 05 01 2007 54 05 01 2007 55 05 01 2007 12 05 01 2007 56 05 01 2007...
Page 15 BRP-Powertrain Maintenance Manual Chapter Page Chapter Page Date Date 10 05 01 2007 53 07 01 2008 11 05 01 2007 54 07 01 2008 12 05 01 2007 55 07 01 2008 13 05 01 2007 56 07 01 2008 14 05 01 2007 57 07 01 2008 15 05 01 2007...
Page 16 BRP-Powertrain Maintenance Manual Chapter Page Chapter Page Date Date 12 05 01 2007 13 05 01 2007 14 05 01 2007 15 05 01 2007 16 05 01 2007 17 05 01 2007 18 07 01 2008 19 10 01 2010 20 10 01 2010 21 10 01 2010 22 05 01 2007...
Page 17 BRP-Rotax Maintenance Manual NOTES 00-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 17 May 01/2007...
Page 18 BRP-Rotax Maintenance Manual NOTES 00-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 18 May 01/2007...
Page 19: Table Of Amendments
BRP-Powertrain Maintenance Manual 5) Table of amendments *Approval The technical content of this document is approved under the authority of DOA Nr. EASA.21J.048. 08215 Ser. Date Sign Date of Date of Sign/ No. Section Pages accept. of implemen- Signature correction acceptance resp.
Page 20 BRP-Powertrain Maintenance Manual Ser. Date Sign Date of Date of Sign/ Section Pages accept. of implemen- Signature correction acceptance resp. authority tation 72-00-00 1,8-10,12,14,18-19, 10 01 2010 DOA* 22, 24-30, 32-35, 40,42, 52-55, 58-59, 63,69,80-81,83-84, 86,88, 92-93,98, 106,108,111 73-00-00 1, 6-7, 15-19, 23-24, 10 01 2010 DOA* 27,29- 30, 45-46, 51,54...
Page 21 BRP-Powertrain Maintenance Manual NOTES 00-00-00 Effectivity 912/914 Series Edition 1 / Rev. 3 page 21 October 01/2010...
Page 22 BRP-Powertrain Maintenance Manual NOTES 00-00-00 Effectivity 912/914 Series Edition 1 / Rev. 3 page 22 October 01/2010...
Page 23: General Note
Maintenance Manual (Line Maintenance) for the respective engine type 912 Series or 914 Series. If any passages of this Manual are not clearly understood or if you have any questions, please contact an authorized distributor or Service Center for ROTAX aircraft engines. 00-00-00 Effectivity 912/914 Series Edition 1 / Rev.
Page 24 BRP-Rotax Maintenance Manual NOTES 00-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 24 May 01/2007...
Page 25: Safety Notice
The information and components/system descriptions contained in this Maintenance Manual are correct at the time of publication. BRP-Rotax maintains a policy of continuous improvement of its products, without, however, incurring any obligation to install them on its products previously manufactured.
Page 26 BRP-Powertrain Maintenance Manual NOTES 00-00-00 Effectivity 912/914 Series Edition 1 / Rev. 3 page 26 October 01/2010...
Page 27: Technical Documentation
BRP-Powertrain Maintenance Manual 8) Technical documentation See also the corresponding Maintenance Manual (Line Maintenance) for the re- spective engine type 912 Series or 914 Series. 8.1) Filling in the dimension sheets See Fig. 00-1 All measurements must be entered in the corresponding dimension sheets as shown.
Page 28: List Of Abbreviations
BRP-Powertrain Maintenance Manual Dimensional check of parts See Fig. 00-2 Take readings of all parts listed in the dimension sheets. Enter the respective actual value in the dimension sheets attached directly after each section. ■ CAUTION: Where measurement values are taken in hundredths of a millimeter or more precisely, the temperature of the part must be 20 to 25 °C (68 to 77 °F).
Page 29: Classification Of Parts For Maintenance/Repair
BRP-Powertrain Maintenance Manual 9) Classification of parts for maintenance/repair See Figs. 00-3 and 00-4. As for an overhaul, parts for maintenance/repair must be classified. They are classified either as “parts usable” or as “parts to be replaced”. The classification is made on the basis of the following criteria: –...
Page 30 BRP-Powertrain Maintenance Manual For engines of Series 912: Fig . 00-3 08677 TSN [h] max. permissible wear max. permissible wear for (Time Since New) for repair [%] repair [%] TBO 1500 - 912 Series TBO 2000 - 912 Series from 1000 1001 1100...
Page 31 BRP-Powertrain Maintenance Manual For engines of Series 914: Fig . 00-4 08679 TSN [h] max. permissible wear max. permissible wear (Time Since New) for repair [%] for repair [%] TBO 1200 - 914 Series TBO 2000 - 914 Series from 1000 1001 1100...
Page 32: Determination Of Actual Wear [%]
BRP-Powertrain Maintenance Manual 9.1) Determination of actual wear [%] See Figs. 00-5, 00-6 and 00-7. Determine actual dimension F of the part in question. For new dimension (max) B and wear limit C, see the corresponding section´Wear limits“ (e. g. 74-00-00 sec. 4). Fig.
Page 33 BRP-Powertrain Maintenance Manual ■ CAUTION: New dimension (max) B is always the dimension which is closest to wear limit C. Fig. 00-7 07564 Procedure for classification of “On Condition Parts” at maintenance/ repair: ◆ NOTE: A negative result means that the actual dimension F is within the new dimension tolerance D.
Page 34 BRP-Powertrain Maintenance Manual NOTES 00-00-00 Effectivity 912/914 Series Edition 1 / Rev. 3 page 34 October 01/2010...
Page 35: Maintenance
See the respective sections in the Operators Manual for the corresponding engine type in the 912/914 Series. 10.2) Tightening torques In general, all screw connections on ROTAX engines must be tightened using a torque wrench. If not specified otherwise for a component, tighten screw connections to the following torque: 4 Nm (35 in.lb)
Page 36: Consumable Materials
BRP-Powertrain Maintenance Manual 10.3) Consumable materials ▲ WARNING: Use only the specified or technically equivalent materials for all maintenance work. The materials listed have undergone longterm testing and are suitable for all operating conditions indicated by the manufacturer. ▲ WARNING: When handling chemicals, comply with all the customary regu- lations and specifications of the producer, including the expiry date.
Page 37 BRP-Powertrain Maintenance Manual 14 899791 LOCTITE 5910 flange sealant provides flexibility and adhesion ...50 ml 15 n.a. LOCTITE 7063 for degreasing and cleaning surfaces....as required SILICONE HEAT CONDUCTION COMPOUND ..150 g 16 897186 Application of the heat conduction compound will reduce heat transfer resistance.
Page 38 BRP-Powertrain Maintenance Manual 22 898570 Screw securing paint seals screws ..............20 ml 23 n.a. Cleaning agent ▲ WARNING: Use only approved cleaning agents (e.g. varsol, etc.) for cleaning metal parts. Do not use lyebased cold cleaners or degreasing agents. Do not clean coolant and oil hoses with aggressive solu- tions.
Page 39: Auxiliary Tools
BRP-Powertrain Maintenance Manual 10.4) Auxiliary tools – compression tester or 2 pressure gauges with calibrated orifice, adapter for dial gauge in spark plug thread – valve spring mounting pliers – step punch for valve guide – adjustable reamer 6.5 to 7.5 mm (0.256 to 0.295 in.) –...
Page 40 BRP-Powertrain Maintenance Manual Disassembly device for propeller gearbox. Fig. 00-8 shows one possible tensioning device for the disassembly of the propeller gearbox. The dimensions given are only intended for easier orientation and are not binding. Fig. 00-8 (0.2 in.) (3.15 in.) (1.89 in.) (1 in.) (0.2 in.)
Page 41: Measuring Tools
BRP-Powertrain Maintenance Manual 10.5) Measuring tools Calliper rule, dial gauge indicator, micrometer, inner micrometer, inner fine measuring device, feeler gauge, spring scale up to 50 kp (500 N)(112.5 lbf). Stroboscope: BOSCH 0 684 100 308 or equivalent. Supply voltage 8 to 15 V.
Page 42 BRP-Powertrain Maintenance Manual 10.6) Special tools and devices See Figs. 00-9, 00-10 and 00-11. The following tools and devices are also listed in the Illustrated Parts Catalog. Fig. No. Part No. Description, application Number 276282 spark plug wrench a/f 16 ........1 276280 spark plug wrench a/f 18 ........
Page 43 BRP-Powertrain Maintenance Manual Fig. No. Part No. Description, application Number 877295 piston ring retainer assy......... 1 for water pump impeller 240381 hex. screw M6x12 ..........1 for float level gauge 17-18 877730 float level gauge assy., .......... 1 for check of float lever 877320 press-in ring ............
Page 44 BRP-Powertrain Maintenance Manual Fig. No. Part No. Description, application Number 877315 graduated straightedge assy........1 for checking the plain bearing projection 876950 precision dial gauge ..........1 877710 dial gauge adapter assy., ........1 877300 aligning plate ............1 877262 cylinder aligning tool ..........
Page 45 BRP-Powertrain Maintenance Manual Fig. No. Part No. Description, application Number 842585 hex. nut M24x1.5 length 19 ........1 941180 stud M10x45/20 ............. 1 for roller bearing 25x52x15 and oil seal 30x52x7 877600 press-out mushroom ..........1 for propeller shaft F3 and F4 877605 press-out mushroom ..........
Page 46 BRP-Powertrain Maintenance Manual Fig. 00-9 08201 00-00-00 Effectivity 912/914 Series Edition 1 / Rev. 3 page 46 October 01/2010...
Page 47 BRP-Powertrain Maintenance Manual Fig. 00-10 08202 00-00-00 Effectivity 912/914 Series Edition 1 / Rev. 3 page 47 October 01/2010...
Page 48 BRP-Powertrain Maintenance Manual Fig. 00-11 08203 00-00-00 Effectivity 912/914 Series Edition 1 / Rev. 3 page 48 October 01/2010...
Page 49 BRP-Rotax Maintenance Manual SECTION 71 POWER PLANT 1) Table of contents SECTION 71 POWER PLANT 1) Table of contents ..................71-00-00 / 1 2) System description ................. 71-00-00 / 3 2.1) Description of design ..............71-00-00 / 3 2.2) Type description ................71-00-00 / 4 2.3) Engine components, engine views, cylinder designation...
Page 50 BRP-Rotax Maintenance Manual NOTES 71-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 2 May 01/2007...
Page 51: System Description
2) System description 2.1) Description of design All ROTAX engines of the 912/914 Series consist of several main components and additional aggregates which are described in the following sections. On the 912 Series: 4-cylinder horizontally opposed 4 stroke engine with a central camshaft pushrods OHV.
Page 52: Type Description
BRP-Rotax Maintenance Manual 2.2) Type description e.g. ROTAX 914 F 2 ◆ NOTE: The type description is composed as follows: ROTAX 02091 914 4-cylinder horizontally opposed turbo engine Type: certified in accordance with FAR/ JAR-E (TW10 - ACG) Certification: F...
Page 53 BRP-Rotax Maintenance Manual 2.3) Engine components, engine views, cylinder designation and descrip- tion of main axes See Figs. 71-1 to 71-4 for engines of the 912 Series See Figs. 71-5 to 71-9 for engines of the 914 Series AS power take off side...
Page 54 BRP-Rotax Maintenance Manual 912 Series Fig . 71-1 Side view Cyl. 2-4 00502 (13) Connection for oil return line (engine) Engine number (14) Oil filter Propeller flange (15) Electric starter Propeller gearbox (16) Electronic module Vacuum pump or hydraulically controlled...
Page 55 BRP-Rotax Maintenance Manual 912 Series Fig. 71-2 00503 Front view Fig. 71-4 912 Series Fig. 71-3 00124 Cyl. 3 Cyl. 4 Cyl. 2 Cyl. 1 Top view 07902 71-00-00 Effectivity 912 Series Edition 1 / Rev. 0 page 7 May 01/2007...
Page 56 BRP-Rotax Maintenance Manual 914 Series Side view Cyl. 2-4 00120 Fig. 71-5 Engine number (24) Electric starter Propeller flange (25) Electronic module Propeller gearbox (26) Compensation tube Vacuum pump or hydraulically controlled (27) Connection for boost pressure display constant speed propeller governor...
Page 57 BRP-Rotax Maintenance Manual 914 Series Fig. 71-6 Front view 00121 914 Series Fig. 71-7 00123 Fig. 71-8 Cyl. 4 Cyl. 3 Cyl. 2 Cyl. 1 Fig. 71-9 00122 Top view 00124 71-00-00 Effectivity 914 Series Edition 1 / Rev. 0...
Page 58 BRP-Rotax Maintenance Manual NOTES 71-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 10 May 01/2007...
Page 59: Technical Data
BRP-Rotax Maintenance Manual 3) Technical data ■ CAUTION: The technical data relevant for engine operation are listed in detail in the respective Operators Manual and must be observed. 3.1) Operating limits See latest version of valid Operators Manual for the engine in question 912 Series or 914 Series, ¨Operating instructions“.
Page 60: Engine / Components
BRP-Powertrain Maintenance Manual 3.4) Engine / Components DESIGN: 4-cylinder horizontally opposed 4-stroke-engine BORE: 79.5 mm (3.13 in.) 84 mm (3.31 in.) 1) 3) STROKE: 61.0mm (2.40in.) DISPLACEMENT: 1211.2 cm³ 1352 cm³ 1) 3) CYLINDER: Lightweight metal cylinder with Nikasil coated running surface PISTON: Lightweight cast metal piston with 3 piston rings...
Page 61 BRP-Powertrain Maintenance Manual IGNITION UNIT: ROTAX DCDI, interference suppressed IGNITION POINT: new 966727 current 966726 Differences between electronic module part no. 966726 and part no. 966727: fly wheel hub 4° Before T.D.C. ignition point at start 966871 current 4° Before T.D.C.
Page 62 BRP-Powertrain Maintenance Manual DIRECTION OF counterclockwise, seen from the front in the direc- ROTATION: tion of the propeller flange OVERLOAD CLUTCH: multi-disk clutch VACUUM PUMP drive via the gearbox (optional): PROPELLER PITCH drive via the gearbox GOVERNOR (optional): TURBOCHARGER: Exhaust gas turbine with wastegate, radial-flow com- pressor T25 TURBOCHARGER electronic, proportional plus integral plus derivative...
Page 63: Treatment Of Corrosion And Surface Damage
BRP-Rotax Maintenance Manual 4) Treatment of corrosion and surface damage In the case of long standstill times, a rust film may form on various metal parts. Severely or heavily corroded screws, nuts, washers, bearings, bushes etc., must be replaced. 4.1)
Page 64 BRP-Rotax Maintenance Manual NOTES 71-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 16 May 01/2007...
Page 65: Preservation And Returning To Service
▲ WARNING: The engine must not be taken into operation. ◆ NOTE: The maximum possible storage period of the engine is limited to 24 months. If this period is exceeded, the engine must be sent to an ROTAX authorized overhaul facility for inspection. 71-00-00 Effectivity 912/914 Series Edition 1 / Rev.
Page 66: Preservation Of An Engine Which Has Been In Operation
– Oil change see latest issue Maintenance Manual (Line Maintenance) for the respective engine type, 912 Series or 914 Series. – On the ROTAX 912 Series: Run the engine to allow it to warm up, leave it running at increased idle speed, remove the air filters and inject approx. 30 of preservation oil into the carburetors, shut down the engine.
Page 67: Maintenance
BRP-Rotax Maintenance Manual 6) Maintenance The following sections describe maintenance procedure for engines of the 912/914 Series above and beyond the maintenance and special checks, see latest issue Maintenance Manual (Line Maintenance) for the respective engine type, 912 Series or 914 Series, and the systems descriptions given hitherto.
Page 68: 2) Engine Suspension Frame Inspection
BRP-Powertrain Maintenance Manual 6.1.2) Engine suspension frame inspection See Fig. 71-11 – All components must be subjected to a visual inspection. ■ CAUTION: If the engine is fitted with engine suspension frame part no. 886567, inspection in accordance with SB-912-028 or SB-914-016,“Checking or replacement of engine suspension frame“, latest issue must be performed.
Page 69 BRP-Rotax Maintenance Manual Fig. 71-10 00164 Fig. 71-11 03080 71-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 21 May 01/2007...
Page 70: Temperature- And Pressure Observation
BRP-Rotax Maintenance Manual 6.2) Temperature- and pressure observation Engines of the 912 Series and 914 Series are equipped with two tempera- ture control points on the cylinder heads for the coolant, one temperature control point for the oil temperature and a pressure control point for the oil pressure.
Page 71 BRP-Powertrain Maintenance Manual SECTION 72 ENGINE 1) Table of contents SECTION 72 ENGINE 1) Table of contents ..................72-00-00 / 1 2) Systems description ................. 72-00-00 / 5 2.1) Propeller gearbox ................72-00-00 / 5 2.1.1) Gearbox version ..............72-00-00 / 5 2.2) Hydraulic governor ................
Page 72 BRP-Rotax Maintenance Manual 3.9) Propeller gearbox................72-00-00 / 22 3.9.1) Removal of roller bearing for - Series 2 ........ 72-00-00 / 24 3.9.2) Removal of roller bearing for - Series 3 ........ 72-00-00 / 26 3.9.3) Removal of roller bearing for - Series 4 ........ 72-00-00 / 27 3.9.4) Propeller gearbox disassembly ..........
Page 73 4) Wear limits ....................72-00-00 / 97 5) Form Sheets ................... 72-00-00 / 117 5.1) Form sheet for material testing ROTAX 912/914 Series ....72-00-00 / 117 5.1.1) Inspection on cracks ............. 72-00-00 / 117 5.1.2) Hardness test ............... 72-00-00 / 117...
Page 74 BRP-Rotax Maintenance Manual NOTES 72-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 4 May 01/2007...
Page 75: Systems Description
BRP-Rotax Maintenance Manual 2) Systems description 2.1) Propeller gearbox See Fig. 72 -1 Transmission gear ratio crankshaft: propeller shaft 2.43 : 1 ; 2.27 : 1 2), 3), 4) The propeller shaft is driven by the crankshaft via a straight toothed spur gear (1).
Page 76 BRP-Rotax Maintenance Manual Fig. 72-1 08204 Configuration 3 with overload clutch 72-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 6 May 01/2007...
Page 77: Hydraulic Governor
BRP-Rotax Maintenance Manual 2.2) Hydraulic governor See Fig. 72 -2 ◆ NOTE: Not included in the range of delivery. A hydraulic governor can be fitted on engines of the 912/914 Series configu- ration 3 to control a hydraulic constant speed propeller. Engines of the 912/ 914 Series configurations 2 and 4 can be retrofitted for this purpose.
Page 78: Vacuum Pump
BRP-Powertrain Maintenance Manual 2.3) Vacuum pump It is possible to install a vacuum pump for employment of an inertial navigation system. To do this, the drive kit for the vacuum pump must be retrofitted on propeller gearbox and crankcase. ◆ NOTE: Installation of both the vacuum pump and hydraulic governor is not possible.
Page 79: Maintenance
BRP-Powertrain Maintenance Manual 3) Maintenance The following sections describe maintenance procedure for engines of the 912/914 Series above and beyond the maintenance and special checks, see latest issue Maintenance Manual (Line Maintenance) for the respective engine type, 912 Series or 914 Series, and the systems descriptions given hitherto.
Page 80: Governor Removal And Inspection
BRP-Powertrain Maintenance Manual 3.2) Governor removal and inspection See Fig. 72-34 in 72-00-00. CAUTION : Observe the governor manufacturers specifications for mainte- ■ nance and repairs! Unscrew the 3 allen screws (16) M8x40 and the 1 allen screw (17) M8x35 and remove together with the lock washers.
Page 81: Ignition Housing Removal And Inspection
BRP-Rotax Maintenance Manual 3.4) Ignition housing removal and inspection See Figs. 72-5, 72-6, 72-7 and 72-8. Cut the tie wraps and remove the cable clamp from the electronic module. Detach the plug connections of the two pickup cables and the plug connections of the charging cable.
Page 82 BRP-Powertrain Maintenance Manual Fig. 72-6 00381 00382 Carry out a visual inspection of the sealing surfaces. Clean oil duct (10) with compressed air and check for free passage. Measure the bearing bore Ø32 (1.26“) mm of the bearing bushing (11) (dimension (IH01)) for the crankshaft bearing (dimension (CS05)) and determine the clearance.
Page 83 BRP-Rotax Maintenance Manual Fig. 72-7 Fig. 72-8 00084 00383 72-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 13 May 01/2007...
Page 84: Ignition Housing Fitting
BRP-Powertrain Maintenance Manual 3.5) Ignition housing fitting See Fig. 72-9. Install the intermediate gear. See 72-00-00 sec. 3.7. ■ CAUTION: If the mounting sleeve, part no. 877360, is not used, the oil seal will be damaged by the sharp edge of the keyway in the crankshaft.
Page 85: Sprag Clutch
BRP-Rotax Maintenance Manual 3.6) Sprag clutch See Figs. 72-10 and 72-12. After removing the fly wheel hub and the ignition housing, see 72-00-00 sec. 3.1 and 72-00-00 sec. 3.4, measure the axial clearance (ES10) of the free wheel gear (6).
Page 86: 1) Sprag Clutch Removal
BRP-Rotax Maintenance Manual 3.6.1) Sprag clutch removal See Fig. 72-11. Lock the crankshaft. See the latest issue Maintenance Manual (Line Maintenance) for the respective engine type, 912 Series or 914 Series. Pull out the intermediate gear shaft (1) and remove the intermediate starter gear (2) with the thrust washers 12.5/21.5/1 (3) on both sides...
Page 87: 2) Sprag Clutch Dismantling
BRP-Rotax Maintenance Manual 3.6.2) Sprag clutch dismantling See Figs. 72-12 and 72-13. Carry out a visual inspection to check whether oil sludge has been deposited in the sprag clutch housing (5) and in in the lock (16). For inspection/cleaning purposes, remove the circlip (14). Compress the circlip (19) in the sprag clutch (17) slightly with circlip pliers and twist the sprag unit out of the sprag clutch housing.
Page 88: 3) Sprag Clutch Installation
BRP-Powertrain Maintenance Manual 3.6.3) Sprag clutch installation See Figs. 72-10, 72-11, 72-12, 72-13, 72-14 and 72-15. Place the sprag clutch into the sprag clutch housing so that the circlip (19) is visible. To fit the circlip, compress it slightly using circlip pliers and ensure that clip remains in position and engages fully on the catches in the sprag unit (20).
Page 89 BRP-Powertrain Maintenance Manual Secure degreased hex. nut M34x1.5 with LOCTITE 648 and tighten to 120 Nm (88.5 ft.lb). ◆ NOTE: Hex. nut has lefthanded thread! ■ CAUTION : Check axial clearance of free wheel gear, see Fig. 72-10 and dimension (ES10) in 72-00-00 sec. 4. im Eingriff / frei drehbar / engaged...
Page 90: Reduction Gear For Electric Starter
BRP-Rotax Maintenance Manual 3.7) Reduction gear for electric starter See Fig. 72-16. Place thrust washer (1) 12.5/21.5/1 on the crankcase. Place interme- diate gear (2) in position, oil intermediate gear shaft (3) and push into position. Place thrust washer (4) 12.5/21.5/1 on top.
Page 91: Rev Counter Drive
BRP-Rotax Maintenance Manual 3.8) Rev counter drive See Figs. 72-17, 72-18 and 72-19. The optional mechanical rev counter (1) is driven via the worm gear pressed into the camshaft. ◆ NOTE: On older engine versions without a mechanical rev counter, a cover plate is fitted in place of the rev counter housing.
Page 92: Propeller Gearbox
BRP-Powertrain Maintenance Manual 3.9) Propeller gearbox See Figs. 72-20, 72-20/1 and 72-21. Before removing the gearbox, it is advisable to check the friction torque. See the corresponding Maintenance Manual (Line Maintenance) for the respective engine type, 912 Series or 914 Series. ■...
Page 93 BRP-Rotax Maintenance Manual 00244 Fig. 72-20 08388 Fig. 72-20/1 Fig. 72-21 LOCTITE 648 00247 72-00-00 Effectivity 912/914 Series Edition 1 / Rev. 1 page 23 January 01/2008...
Page 94 BRP-Powertrain Maintenance Manual Propeller shock load - Inspection of crankshaft distortion on installed crankshaft See Figs. 72-21/1 to 72-21/3 ◆ NOTE: The inspection of the crankshaft only makes sense if the shaft runout of the crankshaft AS or MS is less than 0.080 mm (0.0031 inch) (A) Carefully mount holder (1) for protractor (2) part no.
Page 95 BRP-Powertrain Maintenance Manual Fig. 72-21/2 08582 (D) Turn the crankshaft carefully in direction of engine rotation until the piston touches the piston stoppers. ◆ NOTE: Allways turn the crankshaft in direction of engine rotation, to move the piston towards the piston stopper. ◆...
Page 96 The value can be positive or negative. ■ CAUTION: If a value exceeds the GB20 limit, then the engine needs to be overhauled by a ROTAX-authorised service partner. ■ CAUTION: The deviation of the crank pin (as a whole) must not exceed the GB20 value.
Page 97: 1) Removal Of Roller Bearing For - Series 2
BRP-Powertrain Maintenance Manual Example showing the results from meassuring a crankshaft, where the GB20 threshold is exceeded: Cylinder deviation 0° + 2° 0° -1° Fig. 72-21/4 08691 3.9.1) Removal of roller bearing for - Series 2 See Fig. 72-22. After the propeller gearbox is removed, the crankcase side propeller shaft bearing and oil seal can be replaced if necessary.
Page 98: 2) Removal Of Roller Bearing For - Series 3
BRP-Powertrain Maintenance Manual Keep pull-in spindle in position with the handle lever and turn the hex. nut clockwise until the roller bearing (7) with oil seal (10) is pulled out of the housing. Unscrew hex. nut, remove pullout plate with roller bearing and oil seal and withdraw spindle (11).
Page 99: 3) Removal Of Roller Bearing For - Series 4
BRP-Powertrain Maintenance Manual 3.9.3) Removal of roller bearing for - Series 4 See Fig. 72-24. After the propeller gearbox is removed, the crankcase side propeller shaft bearing can be replaced if necessary. For the extracting procedure it is necessary to drill a bore (2) of at least 6.2 mm dia., (1/4") into the center of the oil inlet cover (1).
Page 100: 4) Propeller Gearbox Disassembly
Remove the complete overload clutch (7) or dog hub (13), disc springs (8) 80x35x3, step collar (9), 6 mm (0.236 in.) distance sleeve (17), compensating shim (10), eccenter (11) (for fuel pump on the ROTAX 912 Series, of no significance on the 914 Series) and 8 mm (0.31in.) distance sleeve (12).
Page 101 BRP-Powertrain Maintenance Manual Fig. 72-26 Fig. 72-25 00261 00260 Fig. 72-27 Dog hub 07704 Overload clutch 72-00-00 Effectivity 912/914 Series Edition 1 / Rev. 3 page 29 October 01/2010...
Page 102: 5) Propeller Shaft Removal
BRP-Powertrain Maintenance Manual 3.9.5) Propeller shaft removal See Figs. 72-28 and 72-29. Place gearbox housing on a suitable surface and press out the propeller shaft with a hand press. Alternatively, the extractor (1), part no. 877615, can be used to press out the propeller shaft. Fit the extractor onto the gearbox housing (3) with 6 x M6 screws (2) and place press-out insert (4), part no.
Page 103 BRP-Rotax Maintenance Manual Fig. 72-28 Fig. 72-29 00263 00264 72-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 31 May 01/2007...
Page 104: 6) Vacuum Pump Drive Removal
BRP-Powertrain Maintenance Manual 3.9.6) Vacuum pump drive removal See Fig. 72-30. The vacuum pump is driven via the drive gear (1) fitted on the propeller shaft. Check the ball bearing (2) and the needle sleeve (3). Check the gear- tooth system of drive gear (1), the vacuum pump gear (4), the drive sleeve (5) and the drive shaft of the vacuum pump.
Page 105: 7) Propeller Governor Drive Removal
BRP-Powertrain Maintenance Manual 3.9.7) Propeller governor drive removal See Figs. 72-31 and 72-32. Remove banjo bolts (1) M10x1 and both sealing rings (2) from the governor flange (3) and the oil pump housing and remove the oil line. Remove the 4 allen screws (4) M6x20 and 2 allen screws (5) M6x16 for oil inlet flange fixation.
Page 106 BRP-Powertrain Maintenance Manual Fig. 72-32 00257 Measure the inner diameter (13) of the propeller shaft and the bearing neck (14) of the oil inlet flange (GB05 and GB06). Any wear will probably appear as a flat area on the journal. Check the gear-tooth system of the drive gear (15) and the vacuum pump gear (8).
Page 107 BRP-Powertrain Maintenance Manual 3.9.8) Propeller governor drive installation See Figs. 72-32, 72-33 and 72-34. ■ CAUTION : The oil inlet flange must be properly aligned and the O- ring must not be squeezed. Install needle sleeve and ball bearing as described in 72-00-00 sec. 3.9.9.
Page 108 BRP-Rotax Maintenance Manual ■ CAUTION : Longer screws will damage the oil inlet flange. ◆ NOTE: Tightening torque 10 Nm (90 in.lb). The allen screws (12) and (13) are secured with LOCTITE 221. Fit the governor (14) and the new gasket (15). Take care that the gear- tooth system engages.
Page 109 BRP-Rotax Maintenance Manual Fig. 72-34 00259 72-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 37 May 01/2007...
Page 110: 9) Vacuum Pump Drive Installation
BRP-Rotax Maintenance Manual 3.9.9) Vacuum pump drive installation See Figs. 72-34, 72-35 and 72-36. Lubricate new needle sleeve (3). Position puller cap (10), part no. 876489, on vaccum pump side, place press-in insert, part no. 877579, (11) onto the needle sleeve and fix with the hex. nut (12). Turning the hex.
Page 111: 10) Gearbox Components Inspection
BRP-Rotax Maintenance Manual 3.9.10) Gearbox components inspection See Figs. 72-37, 72-38, 72-39, 72-40, 72-41 and 72-42. Clean disassembled gearbox with suitable cleaning agents and check the following parts: — Check that the bearing bushing (1) for crankshaft support bearing in the gear cover fits tightly and measure dimension (GB01).
Page 112 BRP-Powertrain Maintenance Manual Treatment of corrosion damage and surface damage to the propel- ler flange The flange of the propeller shaft is subject to corrosion. After wrapping the propeller shaft (2) in plastic tape or covering it with plastic tubing, the propeller flange can be treated with an abrasive.
Page 113 BRP-Rotax Maintenance Manual — Carry out a visual inspection of the dog gear (11) and the dog hub (12) to establish whether pitting is visible on the gear-tooth system and/or the sliding ramps (GB08) of the dogs. Ensure that the ramp tops of the dog gear are clearing the ramp valleys of the dog hub.
Page 114 BRP-Powertrain Maintenance Manual Fig. 72-41 00269 — If there is visible wear to the disc springs (18) in the contact area (19), they must be replaced. Check dimension (GB13) of the uncompressed disc spring. See 72-00-00 sec. 4. Fig. 72-42 41 ø...
Page 115: 11) Toothed Shaft Profiles Inspection
BRP-Rotax Maintenance Manual 3.9.11) Toothed shaft profiles inspection See Fig. 72-43. There are two important toothed shaft connections in the gearbox. – crankshaft to drive gear – propeller shaft to clutch hub of the overload clutch Carry out a visual inspection of all toothed shaft profiles for damage and wear.
Page 116 BRP-Rotax Maintenance Manual 3.9.12) Gear set inspection The gear set is inspected to detect any damage to the gear-tooth system. ◆ NOTE: The gear set can be inspected with the gearbox installed by using an endoscope with flexible shaft. This...
Page 117 BRP-Rotax Maintenance Manual The speed at which the pitting increases depends on the lubricant used and the load. The pitted area can become so large that the remaining, unaffected tooth flank can no longer transmit the load safely. Further operation of the components in this condition will result in the total destruction of the gear-tooth system.
Page 118 Because of the small size of the pitting shown and the copying process, the pictures may not show the pitting clearly enough. If you are in any doubt, seek assistance by studying technical publications or consult your au- thorized ROTAX distributor or Service Center. 00148 Fig. 72-44 Magn.: approx. 100% 00149 Fig.
Page 119 BRP-Rotax Maintenance Manual Advanced pitting: See Figs. 72-47 and 72-48. Characteristics: Larger areas of breakoff, normally appearing as pitting zones. The breakoff surface usually has a shelllike structure. The total pitting zone may reach a size where it impairs smooth engine running noticeably or the remaining flank surface wears rapidly and is destroyed.
Page 120 BRP-Rotax Maintenance Manual Spallation (large zones of the tooth flank have broken off) See Figs. 72-49 and 72-50. Characteristics: Large triangular areas of the tooth flank have broken off, starting in a grey zone or area of minor pitting on the root of the tooth. The spalling area is of relatively constant depth.
Page 121: 13) Propeller Gearbox Reassembly
BRP-Rotax Maintenance Manual 3.9.13) Propeller gearbox reassembly See Figs. 72-51, 72-52 and 72-53. ◆ NOTE: At the modification of the gearbox (e.g. reduction ratio, retro-fit of overload clutch) the part number on the gearbox housing must be corrected. See Fig. 72-51/1.
Page 122 BRP-Rotax Maintenance Manual ◆ NOTE: Gearboxes without an overload clutch have no third disc spring (17), centering rib or slipper clutch. Instead, they are fitted with a second step collar, see Fig. 72-53. ■ CAUTION : If the disc springs are not well centered, the dog gear cannot be depressed sufficiently to allow insertion of ring halves.
Page 123: 14) Disc Spring Pre-Tension Adjustment (With Overload Clutch)
BRP-Rotax Maintenance Manual 3.9.14) Disc spring pre-tension adjustment (with overload clutch) See Figs. 72-53 and 72-25 (see Section 72-00-00 / 3.9.4). When the propeller shaft assembly is uncompressed, the contact surface (24) for the ring halves must lie in the groove of the propeller shaft 1 mm (0.039 in.) over the upper edge (25).
Page 124 BRP-Powertrain Maintenance Manual Fig. 72-53 Version with Version with dog hub overload clutch disk springs compressed disk springs unloaded 06296 72-00-00 Effectivity 912/914 Series Edition 1 / Rev. 3 page 52 October 01/2010...
Page 125: 16) Propeller Gearbox - Installation
BRP-Powertrain Maintenance Manual 3.9.16) Propeller gearbox — installation See Figs. 72-54, 72-55 and 72-56. Carry out a visual inspection of the crankshaft (1) on the power take off side. Slide drive gear (2) onto the crankshaft (3). ◆ NOTE: Due to the restricted tolerances it can occur that it is difficult to slide the drive gear onto the crankshaft.
Page 126 BRP-Powertrain Maintenance Manual Clean sealing surface of gearbox housing and crankcase. Oil which drains onto the sealing surface will eventually create a leak. Insert both dowel pins 6x20 into crankcase. Grease oil seal for propeller shaft in crankcase. Lubricate bearing bore for propeller shaft. ◆...
Page 127: Cylinder Head - Removal
BRP-Powertrain Maintenance Manual Check the radial gear backlash at the propeller flange (9) with the dial gauge (8), dimension (GB18). See 72-00-00 sec. 4. Check the friction torque. See the relevant Manual (Line Maintenance) 12.00.00 chapter 7 of the corresponding engine type 912 Series and 914 Series.
Page 128 BRP-Rotax Maintenance Manual Keep both push rods (6) in position in the oil return tubes (7), seal oil bore of push rods with finger and remove cylinder head (8). The oil return tubes remain with the cylinder head. Remove O-rings (9) 16x15 from the oil return tubes or from the crankcase (10).
Page 129: Cylinder Head - Disassembly
BRP-Rotax Maintenance Manual 3.11) Cylinder head - disassembly See Fig. 72-59. If the rocker arms are to be dismantled without removing the cylinder head, turn the crankshaft to set the piston of the respective cylinder to ignition T.D.C. so that only little pressure remains on the rocker arm.
Page 130 In the event of more serious leakage, cylinder and cylinder head can be reworked as described in the Overhaul Manual by a ROTAX authorized overhaul facility. If the engine has been "run hot", the hardness of the cylinder head and the cylinder material must be checked.
Page 131 BRP-Powertrain Maintenance Manual 3.11.1) Cylinder head and exhaust manifold studs See Figs. 72-60, 72-61 and 72-62. Studs M8 x 20/23 (1) are for attaching the exhaust manifold. Check for tight fit and any damage. When replacing a stud, it is fitted so that the longer thread (23 mm (0.91 in.)) is screwed into the cylinder head.
Page 132 Maintenance Manual ◆ NOTE: If the rocker arm shaft bearing (CH05) is worn, it can be reworked up to a certain limit. The cylinder head must be sent to a ROTAX authorized overhaul facility for this purpose. Fig. 72-62 07831...
Page 133: 2) Reworking Of The Sealing Surface To The Exhaust Manifold
See Fig. 72-63. Reworking is permissible if there is a leak at the sealing surface (1) to the exhaust manifold. If a rework is necessary, the cylinder head must be sent to a ROTAX authorized overhaul facility for overhaul. Fig. 72-63...
Page 134: 3) Valve Guides
Check diameter of valve stem (1) and inner diameter of valve guide (2), see dimension (VT01) and dimension (CH01). If wear limit is reached, replace valve guide. See 72-00-00 sec. 4. For this procedure, the cylinder head must be sent to a ROTAX authorized overhaul facility for maintenance. Fig. 72-65 Fig. 72-64 CH01 Maß...
Page 135: 4) Valve Seats
The width of the imprint corresponds to the width of the valve seat CH02. ■ CAUTION: If burned spots or deformation are detected, send the cylinder head to a ROTAX authorized overhaul facility for overhaul or repair. See 72-00-00 sec. 4.
Page 136: 5) Valves
BRP-Rotax Maintenance Manual 3.11.5) Valves See Figs. 72-67, 72-68, 72-69 and 72-70. Intake valves are checked as follows: Carry out a visual inspection of the valves for damage and wear. Clean valves, measure valve stem diameter and check valve disk for wear.
Page 137 BRP-Rotax Maintenance Manual Oil carbon residue on up to max 20% of the moving path is permissible. See Fig. 72-67. ■ CAUTION: If there are heavier deposits, the valve may already have overheated and must be replaced. There is a danger of valve fracture at the weld.
Page 138 BRP-Rotax Maintenance Manual Check the valve face for wear caused by pounding VT03. Pounding may occur on the inside and the outside edge of the seat surface and must be measured as shown in Fig. 72-70. See 72-00-00 sec. 4.
Page 139: 6) Valve Springs
BRP-Rotax Maintenance Manual 3.11.6) Valve springs See Figs. 72-71 and 72-72. Carry out a visual inspection of the valve springs for damage and wear. Depending on engine version, dual or single valve spring configurations are planned. However, dual and single valve springs must not be used on the same engine.
Page 140 BRP-Rotax Maintenance Manual To check the spring force, apply a test load (F) (test weight set assy. part no. 976995) and measure the remaining spring length VT04 (measuring fixture part no. 976210). See Fig. 72-72. Test load for dual valve spring configuration: –...
Page 141: 7) Washers
BRP-Powertrain Maintenance Manual 3.11.7) Washers See Figs. 72-73, 72-74 and 72-75. Carry out a visual inspection of the washers for damage and wear. The wear must be measured radially with a dial gauge, starting from the reference area (on the inner part of the valve spring support) in measuring range radius (1) and working towards the outside.
Page 142: 8) Rocker Arm And Rocker Arm Shaft
BRP-Rotax Maintenance Manual 3.11.8) Rocker arm and rocker arm shaft See Figs. 72-76 and 72-77. The rocker arm bearing (1) is lubricated via the hollow pushrod (2) to the ball joint (female) (3). The oil flows through the oil ducts (4) in the rocker arm to lubricate the rocker arm bearing.
Page 143: 1) Rocker Arm With Plastic Bushing
BRP-Rotax Maintenance Manual 3.11.8.1) Rocker arm with plastic bushing See Figs. 72-78, 72-79 and 72-80. In the case of plastic rocker arm bushings (2), it must be ensured that the bushing is of slide fit design. After installa- tion, it must still be possible to rotate it against the rocker arm bore.
Page 144: 2) Rocker Arm With Pressed Sinter Bushing
BRP-Rotax Maintenance Manual 3.11.8.2) Rocker arm with pressed sinter bushing See Fig. 72-81. See 72-00-00 sec. 4. The bearing bush cannot be replaced. If the rocker arm is worn, it must be replaced with a rocker arm with a plastic bushing.
Page 145: Cylinder Head Reassembly
BRP-Rotax Maintenance Manual 3.12) Cylinder head reassembly See Fig. 72-83. Place valve spring support (1) in position on the valve guide and fit new valve stem seal (2) on inlet side only. Push oiled intake valve (3) into the valve guide from the outside, slide on both valve springs (outside (4) and inside (5)) or single valve spring (17) and the valve spring retainer (6).
Page 146 BRP-Rotax Maintenance Manual Fig. 72-83 07707 72-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 74 May 01/2007...
Page 147: Cylinder And Piston - Removal
BRP-Rotax Maintenance Manual 3.13) Cylinder and piston - removal See Figs. 72-84 and 72-85. ◆ NOTE: Prior to removal, mark cylinders and pistons in pairs to ensure correct coordination on re-assembly. The cylinders are all identical in design. The piston pin center is offset from piston center.
Page 148 BRP-Rotax Maintenance Manual Push out piston pin using installation tool, part no. 877016. If the piston pin is fitted too tightly, it can be pulled out using the piston pin extraction tool (4), part no. 877090, see 00-00-00 sec. 10.6. Insert the pullout spindle (5) into the piston pin (6) and screw on the nut (7).
Page 149: 1) Checking Pistons
BRP-Rotax Maintenance Manual 3.13.1) Checking pistons See Figs. 72-86 and 72-87. On engines of the 912/914 Series, light alloy full skirt cast pistons are used. The piston axis is offset by 1 mm (0.039 in.). Remove piston rings using a pair of piston ring pliers. Make absolutely sure to re-fit rings in their initial position.
Page 150 BRP-Rotax Maintenance Manual Fig. 72-86 PI02 PI02 PI01 13mm (0.51 in) 07435 Fig. 72-87 Pl04 Pl05 Pl06 07412 72-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 78 May 01/2007...
Page 151: 2) Checking The Piston Ring
BRP-Rotax Maintenance Manual 3.13.2) Checking the piston ring See Figs. 72-88 and 72-89. Check the end clearance of the cleaned piston rings. To determine the end clearance (4), remove the piston rings from the piston using piston ring pliers, clean them and insert into the cylinder.
Page 152: 3) Piston Pin
BRP-Powertrain Maintenance Manual 3.13.3) Piston pin See Fig. 72-90 Measure piston pin and check for traces of seizure in area of con-rod seat. In case of distinct traces of seizure, replace piston pin even if dimensions are correct. Measure dimension PI03. See 72-00-00 sec.
Page 153: 4) Cylinders Inspection
BRP-Powertrain Maintenance Manual 3.13.4) Cylinders inspection See Figs. 72-91, 72-92 and 72-93. The running surface of the cylinder is "NICKEL-SILICON"coated. All 4 cylinders are identical. Clean the cooling fins (1) of the cylinder. Remove oil carbon deposits from the top end (2) of the cylinder bore. Clean sealing surfaces on top (3) and bottom sides (4) and inspect cylinder.
Page 154 BRP-Rotax Maintenance Manual Fig. 72-91 00297 Fig. 72-92 Fig. 72-93 CY03 (0.197 in.) CY04 40mm CY01 (1.57 in.) 76mm CY02 (2.99 in.) 07485 07413 72-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 82 May 01/2007...
Page 155: Hydraulic Valve Tappets
■ CAUTION : If it is necessary to replace a hydraulic valve tappet, make sure that a tappet with a polished cam running surface (ROTAX part no. 881831) is used. Depending on storage conditions, new hydraulic valve tappets are partially emptied and pump full of oil during engine startup.
Page 156 BRP-Powertrain Maintenance Manual Fig. 72-94 00299 Fig. 72-96 Fig. 72-95 00301 00300 Fig. 72-97 07580 72-00-00 Effectivity 912/914 Series Edition 1 / Rev. 3 page 84 October 01/2010...
Page 157: Edition 1 / Rev
BRP-Rotax Maintenance Manual 3.15) Pushrods See Fig. 72-98. Clean push-rods (1) and carry out a visual inspection. Make sure that the two ball heads (2) pressed into the rod fit tightly. Excessive engine speed may have caused bending of the pushrods. Roll push-rods and check for run out, dimension (VT09).
Page 158: Piston And Cylinder Assembly Fitting
BRP-Powertrain Maintenance Manual 3.16) Piston and cylinder assembly fitting 3.16.1) Hydraulic valve tappets fitting Lubricate bearing bore for hydraulic valve tappets in crankcase. Apply LOCTITE Anti-Seize to the contact surfaces of the hydraulic valve tappets, lubricate their circumference and insert them into the crank- case according to the recorded position .
Page 159 BRP-Rotax Maintenance Manual Fig. 72-101 Zylinder 1 und 3 / Zylinder 2 und 4 / auf den Propellerflansch gesehen / Cylinder 1 and 3 Cylinder 2 and 4 looking at propeller flange 00305 Oil the entire length of the piston pin (4). The connecting rod eye (5) and the piston pin bore (6) are also oiled.
Page 160 BRP-Powertrain Maintenance Manual ■ CAUTION: Always use new mono hook circlips! Used retaining rings or retaining rings which have already been fitted have too little tangential tension, can twist and thus wear the groove in the piston. Fit piston pin circlip with installation tool, part no. 877802. To do so, press the mono hook circlip (11) into the groove (14) of the mounting sleeve (13) and push guide punch (12) into the mounting sleeve.
Page 161 BRP-Rotax Maintenance Manual Fig. 72-104 02038 Fig. 72-105 (0.166 in) (0.079 in) 4,2 mm 2 mm 08206 72-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 89 May 01/2007...
Page 162: 3) Cylinders Fitting
BRP-Rotax Maintenance Manual 3.16.3) Cylinders fitting See Fig. 72-106. Place O-ring 87x2 on the cylinder skirt and oil the cylinder wall. ◆ NOTE: On engines with crankcases bearing serial numbers up to S/N 27811, there is an O-ring 87x2 fitted to depress stud bolt M8x297.
Page 163 BRP-Rotax Maintenance Manual ° - 3 0 ° Fig. 72-106 ° - 3 0 ° 05766 72-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 91 May 01/2007...
Page 164: 4) Cylinder Head Fitting
BRP-Powertrain Maintenance Manual 3.16.4) Cylinder head fitting See Figs. 72-107, 72-108, 72-109 and 72-110. Install respective pushrods (1) in both oil return tubes on the pre- assembled cylinder head and place pre-oiled O-ring (2) 16x5 on oil return tube (3). Fit cylinder head until the O-rings (2) on both oil return tubes rest in the crankcase (4).
Page 165 BRP-Powertrain Maintenance Manual Fit valve cover and tighten with allen screw (16) M6x30 and washer (17) to a tightening torque of 10 Nm (90 in.lb). ■ CAUTION : On the outer contour, there must be a gap of at least 0.2 mm (0.008 in.) between the valve covers.
Page 166 BRP-Rotax Maintenance Manual Fig. 72-108 07709 Fig. 72-109 08340 Fig. 72-110 00312 72-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 94 May 01/2007...
Page 167: Intake Manifold And Compensation Tube Assembly
MOLYKOTE G-N 08453 3.18) Crankshaft inspection Measure the crankshaft (CS04, CS05, CS07 und CS24). See 72-00-00 sec. 4. In the case of deviation, the whole assy. engine block must be sent to an ROTAX authorized overhaul facility. 72-00-00 Effectivity 912/914 Series Edition 1 / Rev.
Page 168 BRP-Rotax Maintenance Manual NOTES 72-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 96 May 01/2007...
Page 169: Wear Limits
BRP-Rotax Maintenance Manual 4) Wear limits Kurbelwelle (crankshaft) CS04 CS05 07710 CS07 Kurbelwelle (crankshaft) 07507 07517 72-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 97 May 01/2007...
Page 170 BRP-Powertrain Maintenance Manual 08748 08748 72-00-00 Effectivity 912/914 Series Edition 1 / Rev. 3 page 98 October 01/2010...
Page 171 BRP-Rotax Maintenance Manual PI02 PI02 PI01 13mm (0.51 in.) 07435 PI03 07403 72-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 99 May 01/2007...
Page 172 BRP-Rotax Maintenance Manual Pl04 Pl05 Pl06 07412 07432 PI07 / PI08 / PI09 72-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 100 May 01/2007...
Page 173 BRP-Rotax Maintenance Manual 07221 wear wear Reading new limit limit Description Readings 100% Piston Cyl. 1 Cyl. 2 Cyl. 3 Cyl. 4 actual Piston red 79,488 79,502 79,390 79,439 PI01 79,5 mm / 3,1 in. 3,1294 3,1300 3,1256 3,1275 renewed...
Page 174 BRP-Rotax Maintenance Manual 07221 wear wear Reading new limit limit Description Readings 100% Piston Cyl. 1 Cyl. 2 Cyl. 3 Cyl. 4 actual Pison pin clearance PI02/ 0,006 0,013 0,050 0,032 in piston pin bore PI03 0,0002 0,0005 0,0020 0,0012...

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Mmh-914 series