bpr Rotax 912 i Series Maintenance Manual
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bpr Rotax 912 i Series Maintenance Manual

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AIRCRAFT ENGINES
(HEAVY MAINTENANCE) FOR ROTAX® ENGINE TYPE 912 i SERIES
ref. no.: MMH-912 i | part no.: 898751
picture: ROTAX® 912 iS with options

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Summary of Contents for bpr Rotax 912 i Series

  • Page 1 AIRCRAFT ENGINES (HEAVY MAINTENANCE) FOR ROTAX® ENGINE TYPE 912 i SERIES ref. no.: MMH-912 i | part no.: 898751 picture: ROTAX® 912 iS with options...
  • Page 2 Before starting any maintenance work, please read the Maintenance Manual completely as it contains important safety relevant information. Failure to do so may result in personal injuries including death. Consult the orginal equipment manufacturers handbook for additional instructions! These technical data and the information embodied therein are the property of BRP-Rotax GmbH &...
  • Page 3 BRP-Powertrain MAINTENANCE MANUAL Chapter: INTRO GENERAL NOTE Before carrying out maintenance work on the engine, please read the Foreword Heavy Maintenance Manual carefully. See also the latest revision of the corresponding Line Maintenance Manual for the engine type 912 i 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.
  • Page 4 BRP-Powertrain MAINTENANCE MANUAL Subject Chapter Sensors and actuators Chapter 76-70-00 Exhaust system Chapter 78-00-00 Exhaust Chapter 78-10-00 Lubrication system Chapter 79-00-00 Electric starter Chapter 80-00-00 INTRO Effectivity: 912 i Series Edition 1/Rev. 0 Page 2 July 01/2012...
  • Page 5 BRP-Rotax MAINTENANCE MANUAL Chapter: LEP LIST OF EFFECTIVE PAGES Chapter Page Date Chapter Page Date Title page 00-00-00 2012 07 01 INTRO 2013 10 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2018 07 01 2012 07 01 2018 07 01 2013 10 01...
  • Page 6 BRP-Rotax MAINTENANCE MANUAL Chapter Page Date Chapter Page Date 37-10-00 2012 07 01 71-00-00 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 72-00-00 2012 07 01...
  • Page 7 BRP-Rotax MAINTENANCE MANUAL Chapter Page Date Chapter Page Date 72-20-00 2012 07 01 72-30-10 2012 07 01 2012 07 01 2014 07 01 2012 07 01 2012 07 01 2012 07 01 2014 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01...
  • Page 8 BRP-Rotax MAINTENANCE MANUAL Chapter Page Date Chapter Page Date 73-10-00 2012 07 01 75-00-00 2014 07 01 2012 07 01 2014 07 01 2012 01 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 76-00-00 2012 07 01 2012 07 01 2012 07 01 2012 07 01...
  • Page 9 BRP-Rotax MAINTENANCE MANUAL Chapter Page Date Chapter Page Date 76-50-00 2012 07 01 76-70-00 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 78-00-00 2012 07 01 2012 07 01 2012 07 01 2012 07 01...
  • Page 10 BRP-Rotax MAINTENANCE MANUAL Chapter Page Date 80-00-00 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 Rear page Effectivity: 912 i Series Edition 1/Rev. 3 Page 6 July 01/2018...
  • Page 11 BRP-Rotax MAINTENANCE MANUAL Chapter: TOA TABLE OF AMENDMENTS *Approval The technical content of this document is approved under the authority DOA ref. EASA.21J.048 date of ap- date of remark for date of chapter page proval from signature change approval inclusion authorities INTRO 07 01 2012...
  • Page 12 BRP-Rotax MAINTENANCE MANUAL date of ap- date of remark for date of chapter page proval from signature change approval inclusion authorities 00-00-00 6,8,32 10 01 2013 DOA* 33-36 10 01 2013 DOA* 24-20-00 3,7-10 10 01 2013 DOA* 13-19 10 01 2013 DOA* 76-10-00 1-36...
  • Page 13 BRP-Rotax MAINTENANCE MANUAL Chapter: TOA SUMMARY OF AMENDMENTS Summary of the relevant amendments in this context, but without require- Content ment on completeness. Current date chapter page Comment of change 00-00-00 31 - 36 10 01 2013 Illustration (special tools) added. 24-20-00 10 01 2013 New illustrations, new tooling (see revision bars).
  • Page 14 BRP-Rotax MAINTENANCE MANUAL NOTES Effectivity: 912 i Series Edition 1/Rev. 0 Page 4 July 01/2012...

  • Page 15: Table Of Contents

    GENERAL NOTE This manual describes maintenance of all ROTAX 912 i Series engines. Introduction ROTAX 912 i Series includes 912 iS, 912 iS Sport and 912 iSc Sport. NOTE: This chapter of the Maintenance Manual contains general and safety informa- Table of contents tion concerning a safe operation and maintenance of the aircraft engine.
  • Page 16 BRP-Powertrain MAINTENANCE MANUAL NOTES 00-00-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 2 July 01/2012...

  • Page 17: General Note

    BRP-Powertrain MAINTENANCE MANUAL 1) General note The purpose of this Maintenance Manual is to acquaint maintenance service Purpose staff (iRMT) approved by the local aviation authorities with some basic main- tenance and safety information for service work. For more detailed information regarding, maintenance, safety or flight operation, Documentation consult the documentation provided by the aircraft manufacturer and/or dealer.
  • Page 18 BRP-Powertrain MAINTENANCE MANUAL NOTES 00-00-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 4 July 01/2012...

  • Page 19: Abbreviations And Terms Used In This Manual

    BRP-Powertrain MAINTENANCE MANUAL 2) Abbreviations and terms used in this manual Abbreviations Abbreviation Description Reference to another section center of gravity The drop symbol indicates use of sealing agents, adhesives or lubricants (only in the Illustrated Parts Catalog). °C Degrees Celsius (Centigrade) °F Degrees Fahrenheit 912 iS...
  • Page 20 BRP-Powertrain MAINTENANCE MANUAL Abbreviation Description Engine Management System European Norm Federal Aviation Administration Federal Aviation Regulation FUSE BOX Fuse box hours HIC A Human Interface Connector A HIC B Human Interface Connector B Instrument Flight Rules Installation Manual INJ 1-8 Injector 1-8 INTRO Introduction...
  • Page 21 BRP-Powertrain MAINTENANCE MANUAL Abbreviation Description Society of Automotive Engineers Service Bulletin Service Instruction Service Letter Surface Mounted Devices Serial Number s.v. still valid (only Illustrated Parts Catalog) Table of amendments Type certificate Table of Contents Time Since New TSNP Time Since New Part Time Since Overhaul Volt Visual Flight Rules...

  • Page 22: Conversion Table

    BRP-Powertrain MAINTENANCE MANUAL 2.1) Conversion tabl Units of length: Units of power: 1 mm = 0.03937 in 1 kW = 1.341 hp 1 in = 25.4 mm 1 hp = 0.7457 kW 1 ft = 12 in 1 kW = 1.3596 PS = 0.3048 m 1 PS = 0.7355 kW Units of area:...

  • Page 23: Safety Notice

    BRP-Powertrain MAINTENANCE MANUAL 3) Safety notice Although the reading of such information does not eliminate the hazard, under- General note standing the information will promote its correct use. Always use common work- shop safety practice. The information and components system descriptions contained in this Manual are correct at the time of publication.

  • Page 24: Safety Information

    This Manual has been prepared as a guide to correctly service and maintain all Manual ROTAX 912 i Series engines. This edition was primarily published to be used by aircraft mechanics who are already familiar with all service procedures relating to ROTAX aircraft engines.
  • Page 25 BRP-Powertrain MAINTENANCE MANUAL Torque wrench tightening NOTICE WARNUNG If not specified otherwise, the threads are not lubricated when fastened. Torque wrench tightening specifications must be strictly adhered to. Effectivity: 912 i Series 00-00-00 Edition 1/Rev. 0 Page 11 July 01/2012...

  • Page 26: Instruction

    BRP-Powertrain MAINTENANCE MANUAL 3.2) Instruction Engines require instructions regarding their application, use, operation, main- General note tenance and repair. Technical documentation and directions are useful and necessary complemen- tary elements for personal instruction, but can by no means substitute theoretical and practical instructions.

  • Page 27: Maintenance Concept

    BRP-Powertrain MAINTENANCE MANUAL 3.3) Maintenance concept The maintenance functions detailed in this Manual fall into two categories: General note - Maintenance I (Line Maintenance) - Maintenance II (Heavy Maintenance) Repairs beyond the levels detailed in this Manual are not recommended as maintenance functions and must be done by an authorized overhaul facility.

  • Page 28: Technical Documentation

    BRP-Powertrain MAINTENANCE MANUAL 3.4) Technical documentation These documents form the instructions ensuring continued airworthiness of General note ROTAX aircraft engines. The information contained is based on data and experience that are considered applicable for authorized mechanics (iRMT) under normal conditions. Due to the fast technical progress and fulfilment of particular specifications of the customers it may occur that existing laws, safety prescriptions, constructional and operational regulations cannot be transferred completely to the object...
  • Page 29 BRP-Powertrain MAINTENANCE MANUAL Furthermore the Manual is constructed in such a way that single pages can be Replacement pa- replaced instead of the complete document. The list of effective pages is given in the chapter LEP. The particular edition and revision number is given on the footer of each page.

  • Page 30: Use For Intended Purpose

    BRP-Powertrain MAINTENANCE MANUAL 3.5) Use for intended purpose General note WARNING WARNUNG Never run an engine without propeller. Flying components can cause serious in- juries. The engine ROTAX 912 iSc Sport is intended for use in certified aircraft. In case of doubt the regulations of the national authorities or the respective sportive federations have to be observed.

  • Page 31: Inspection Of Parts And Report Of Findings

    BRP-Powertrain MAINTENANCE MANUAL 4) Inspection of parts and report of findings Fig. 2. General note Measure all parts listed in the dimension sheets. These are attached directly after each section. All measurements must be entered in the corresponding dimension sheets as shown.
  • Page 32 BRP-Powertrain MAINTENANCE MANUAL Fig. 2 07538, 07437 The following table shows the abbreviations used for the control points. List of abbrevia- tions Abbreviation Description alternator camshaft crankcase cylinder head conrod crankshaft cylinder electric electric starter exhaust gearbox governor oil pump piston piston pin stator...

  • Page 33: Classification Of Parts For Maintenance/Repair

    BRP-Powertrain MAINTENANCE MANUAL 5) Classification of parts for maintenance/repair As for an overhaul, parts for maintenance/repair must be classified. They are General note classified either as „parts usable“ („On-Condition“) or as „parts to be replaced“ („100 % Parts“). The classification is made on the basis of following criteria: Criteria - Hours of operation (decisive are the total operating hours of the part/engine or hourse since the last overhaul)
  • Page 34 BRP-Powertrain MAINTENANCE MANUAL TSN [h] max. permissible wear Time Since New for repair [%] from TBO 2000 h - 912 i Series 1501 1600 1601 1700 1701 1800 1801 1900 1901 2000 - Determine actual dimension F of the part in question. Determination of actual wear [%] - For new dimension (max.) B and wear limit C see the corresponding dimen-...
  • Page 35 BRP-Powertrain MAINTENANCE MANUAL Classification of „On-Condition“ parts at maintenance/repair: Classification Fig. 4 08219 A negative result means that the actual dimension F is within the new NOTE: dimension tolerance D and the part can be used again. The hours of operation are indicated with 300 h. The determined percentage of Example maximum permissible wear is therefore 36 %.
  • Page 36 BRP-Powertrain MAINTENANCE MANUAL NOTES 00-00-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 22 July 01/2012...

  • Page 37: Maintenance

    BRP-Powertrain MAINTENANCE MANUAL 6) Maintenance Beyond the maintenance and special checks (see therefore Line Maintenance General note Manual for 912 i Series), as well as the system descriptions hitherto, the following sections describe the maintenance procedures for 912 i Series. The description is subdivided into subsections and descriptions of the fuction of the various sys- tems.
  • Page 38 BRP-Powertrain MAINTENANCE MANUAL Consumable materials WARNING WARNUNG Use only the from BRP-Powertrain specified or technically equivalent materials for all maintenance work. The materials listed have undergone longterm testing of BRP-Powertrain and are suitable for all operating conditions indicated by the manufacturer. WARNING WARNUNG When handling chemicals, comply with all the customary regulations and speci-...
  • Page 39 BRP-Powertrain MAINTENANCE MANUAL Part no. Description, application Qty. 297710 PU-glue 310 ml for shock absorption 898570 Screw securing paint 20 ml seals screws 899789 LOCTITE 603 green 10 ml oil tolerant retaining compound, heavy-duty Effectivity: 912 i Series 00-00-00 Edition 1/Rev. 0 Page 25 July 01/2012...
  • Page 40 BRP-Powertrain MAINTENANCE MANUAL Part no. Description, application Qty. n.a. Cleaning agent as re- quired WARNING WARNUNG 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 solutions. Clean off residues of sealing compound with sealant remo- ver.
  • Page 41 BRP-Powertrain MAINTENANCE MANUAL Part no. Description, application Qty. n.a. Valve lapping paste as re- This paste, produced by various manufacturers, is a fine gra- quired nulate lapping paste for manual lapping of valve seats and valves. The paste is usually available in 3 different granulate sizes.
  • Page 42 BRP-Powertrain MAINTENANCE MANUAL Current circulation for indication of longitudinal cracks. Field circulation for indication of transverse cracks. Auxiliary circulation for indication of axial and radial cracks on parts with bores right through by using an electric auxiliary conductor (copper bar). Measure tangential field intensity with field intensity tester Deutrometer 3870 or with an equivalent field intensity tester.
  • Page 43 BRP-Powertrain MAINTENANCE MANUAL Calliper rule, dial gauge indicator, micrometer, inner micrometer, inner fine mea- Measuring tools suring device, feeler gauge, spring scale up to 50 kp (500 N) (112.5 lbf) Multimeter: Fluke Series 70, Series 80 or equivalent Electronic, 3 1/2 digit indication Current range 10 A Direct voltage range 200 V minimum Ω...
  • Page 44 BRP-Powertrain MAINTENANCE MANUAL Part no. Description, application Qty. 876885 mounting yoke to compress dog gear 877660 puller assy. for gearbox 877540 puller assy. for gearbox 15-18 876489 puller assy. for ball bearing 15x32x8, needle sleeve 22x28x12, oil inlet flange and oil inlet cover 941730 hex.
  • Page 45 BRP-Powertrain MAINTENANCE MANUAL Part no. Description, application Qty. 877155 extracting nut M6 assy. for piston pin extractor 976380 mono hook circlip puller for piston pin circlip 876967 piston ring retainer 84 mm (3.31 in.) 37-38 877375 puller assy. for flywheel hub 940755 hex.
  • Page 46 BRP-Powertrain MAINTENANCE MANUAL Part no. Description, application Qty. 877690 check lever for removal of rocker arms 877316 measuring bar assy. for inspection of plain bearing excess length 877710 dial gauge holder assy. 876950 precision dial gauge 877300 joggling plate 976140 dial gauge adapter assy.
  • Page 47 BRP-Powertrain MAINTENANCE MANUAL Effectivity: 912 i Series 00-00-00 Edition 1/Rev. 1 Page 33 October 01/2013...
  • Page 48 BRP-Powertrain MAINTENANCE MANUAL 00-00-00 Effectivity: 912 i Series Edition 1/Rev. 1 Page 34 October 01/2013...
  • Page 49 BRP-Powertrain MAINTENANCE MANUAL Effectivity: 912 i Series 00-00-00 Edition 1/Rev. 1 Page 35 October 01/2013...
  • Page 50 BRP-Powertrain MAINTENANCE MANUAL NOTES 00-00-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 36 July 01/2012...
  • Page 51 MAINTENANCE MANUAL Chapter: 24-20-00 INTERNAL GENERATOR Introduction This section describes the maintenance of the internal generator assembly of the ROTAX 912 i Series engine. The description is divided into sub-sections and explanations of system functions. Subject Page 1. Introduction Page 1 2.
  • Page 52 BRP-Powertrain MAINTENANCE MANUAL 24-20-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 2 July 01/2012...
  • Page 53 BRP-Powertrain MAINTENANCE MANUAL Chapter: 24-20-00 INTERNAL GENERATOR SPECIAL TOOLS Description Part number Puller assy. 876010 Insertion jig 876020 SERVICE PRODUCTS Description Part number LOCTITE 243 897651 LOCTITE 648 899788 LOCTITE 603 899789 LOCTITE 5910 899791 KLUEBER ISOFLEX TOPAS Nb5051 898351 Polishing cloth n.a.
  • Page 54 BRP-Powertrain MAINTENANCE MANUAL Internal generator 24-20-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 4 July 01/2012...
  • Page 55 BRP-Powertrain MAINTENANCE MANUAL SYSTEM DESCRIPTION MAINTENANCE The ROTAX 912 iSc/iS has an electronically As well as the maintenance and special checks, controlled double-ignition system with an integ- see the relevant Maintenance Manual Line for rated generator. the respective 912 i Series engine type. EMS POWER SUPPLY INTERNAL GENERATOR - REMOVAL The EMS power supply consists essentially of 2...
  • Page 56 BRP-Powertrain MAINTENANCE MANUAL REMOVAL Step Procedure Preparation Loosen the airbox bracket. Loosen the hex. nut and remove it along with the NOTICE WARNUNG washer. Use appropriate protective coverings to prevent Fig. 2 the ingress of foreign bodies into all dis- connected lines and connections.
  • Page 57 BRP-Powertrain MAINTENANCE MANUAL NOTE: The M6x50 Allen screw goes into the Step Procedure crankcase in the case of cylinder 4 (at Remove O-rings from the crankcase or CPS_1) and is secured with LOCTI- the ignition housing. TE 243. The plug screws must be removed and degreased for possible leaks.
  • Page 58 BRP-Powertrain MAINTENANCE MANUAL Fig. 7 STATOR ASSY. - REMOVAL NOTICE WARNUNG Mark cables before removing the connector receptacle. The generator coils A and B have different sizes and powers. Step Procedure Mark cables. Fig. 9 1. Dowel pin 2. Plug screws FLY WHEEL ASSY.
  • Page 59 BRP-Powertrain MAINTENANCE MANUAL Fig. 13 Step Procedure Prise back the retaining tab and at the same time carefully pull on the line until the terminal is detached. Fig. 11 1. M6x16 Allen screw 2. Cable clamp 8/M6 Fig. 14 1. Retaining tab 2.
  • Page 60 BRP-Powertrain MAINTENANCE MANUAL Fig. 17 Fig. 15 1. Lead-through seal 2. Adjustment screw M4x8 1. Stator assy. Step Procedure Loosen 6 M5x30 Allen screws and re- move stator assy. Fig. 16 1. M5x30 Allen screw 2. Washer A 5.5 3. Stator assy. Step Procedure Push the lead-through seal in and pull the...
  • Page 61 BRP-Powertrain MAINTENANCE MANUAL INSPECTION Fig. 19 IGNITION HOUSING - SINGLE PARTS CHECK Preparation - Clean all parts carefully. See also section 05- 00-00 Procedures IGNITION HOUSING - CHECK Step Procedure Carry out visual inspection of sealing sur- faces. Unscrew pressure sensor (oil). To do this, 1.
  • Page 62 BRP-Powertrain MAINTENANCE MANUAL Fig. 21 STATOR ASSY. - INSPECTION NOTICE WARNUNG Danger of consequent damage to engine! The stator may not be post-machined! If the sta- tor or its wiring is damaged or worn, it must be replaced with a new part. NOTICE WARNUNG Signs of wear on the magnet are not permissib-...
  • Page 63 BRP-Powertrain MAINTENANCE MANUAL WEAR LIMITS 06340 Ignition housing Current measurement Tolerance Tolerance value limit limit Description Measurements 100 % 50 % Bearing bushing in ig- IH01 28.04 mm 28.05 mm 28.11 mm 28.08 mm current nition housing 1.104 in. 1.1044 in. 1.1067 in.
  • Page 64 BRP-Powertrain MAINTENANCE MANUAL ASSEMBLY Fig. 25 IGNITION HOUSING - ASSEMBLY Whenever the ignition housing is in- NOTE: stalled or assembled, new, acid-free greased o-rings and other sealing ele- ments must always be used correctly! Step Procedure Polish and then clean the contact surface for the oil seal.
  • Page 65 BRP-Powertrain MAINTENANCE MANUAL Fig. 27 Step Procedure Install the distance sleeve, disk springs and washer. Tighten lock nut M5. Tightening torque 6 Nm (53 in.lb.). Slip on the full length of the black protec- tion hoses. Fig. 29 1. Lead-through seal 2.
  • Page 66 BRP-Powertrain MAINTENANCE MANUAL Fig. 30 Fig. 31 1. Lock Step Procedure Install 8/M6 cable clamps. NOTE: The bends of the cable clamps must be installed in a diametri- cally opposed manner. Adjust cables. Tighten M6x20 Allen screw. Tightening torque 10 Nm (88.48 in. lb.). Fig.
  • Page 67 BRP-Powertrain MAINTENANCE MANUAL INSTALLATION Step Procedure FLY WHEEL ASSY. - INSTALLATION Lubricate oil seal, bearing bushing and crankshaft stub with KLUEBER ISOFLEX Preparation TOPAS Nb5051. Clean all flat surfaces NOTE: Insert 5x2 O-ring into the crankcase and lubricate with KLUEBER ISOFLEX TO- Step Procedure PAS Nb5051 to hold in position.
  • Page 68 BRP-Powertrain MAINTENANCE MANUAL Fig. 37 Step Procedure Turn the water pump wheel slightly so that the gear wheels can mesh. Fasten the ignition housing to the crank- case using Allen screws. Tightening torque 10 Nm (88.48 in. lb.) NOTICE WARNUNG The ignition housing must be attached manually without tapping.
  • Page 69 BRP-Powertrain MAINTENANCE MANUAL The through-bore of the screw pene- No washers are used for these screws, NOTE: NOTE: trates as far as the crankcase. as otherwise the starter does not lie flat The engine is not leakproof if this screw on the flange surface.
  • Page 70 BRP-Powertrain MAINTENANCE MANUAL NOTES 24-20-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 20 July 01/2012...
  • Page 71 MAINTENANCE MANUAL Chapter: 24-30-00 EXTERNAL ALTERNATOR Introduction This section describes the maintenance of the external alternator assembly of the ROTAX 912 i Series engine. The description is divided into sub-sections and explanations of system functions. Subject Page 1. Introduction Page 1 2.
  • Page 72 BRP-Powertrain MAINTENANCE MANUAL Location on the engine 24-30-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 2 July 01/2012...
  • Page 73 BRP-Powertrain MAINTENANCE MANUAL SYSTEM DESCRIPTION MAINTENANCE The ROTAX 912 i Series can optionally be As well as the maintenance and special checks, equipped with an external alternator. This is a see the relevant Maintenance Manual Line for state-of-the-art, electromechanical three-phase the respective 912 i Series engine type.
  • Page 74 BRP-Powertrain MAINTENANCE MANUAL External alternator 24-30-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 4 July 01/2012...
  • Page 75 BRP-Powertrain MAINTENANCE MANUAL REMOVAL Fig. 2 Preparation - Loosen pulley tension. See the most recent Maintenance Manual Line. - Remove the propeller. See "Documentation of aircraft manufacturer" V-BELT PULLEY - REMOVAL Step Procedure Loosen 8 M5x16 Allen screws with lock washers.
  • Page 76 BRP-Powertrain MAINTENANCE MANUAL Fig. 4 1. Alternator bracket 2. Lock washer 3. M8x20 Allen screws Step Procedure Remove 2 M6x50 Allen screws along with lock washers and washers from the gear- box housing and alternator support. Fig. 5 1. Alternator support 2.
  • Page 77 BRP-Powertrain MAINTENANCE MANUAL INSTALLATION Fig. 7 V-BELT PULLEY - INSTALLATION Step Procedure Push the v-belt pulley completely over the propeller flange and insert the 9.5x675 v- belt loosely into the v-belt pulley. Fig. 6 1. M5x16 Allen screws 2. Lock washers 3.
  • Page 78 BRP-Powertrain MAINTENANCE MANUAL Fig. 9 Fig. 11 1. Alternator bracket 2. Lock washers 1. V-belt 2. M8x20 Allen screw 3. M8x20 Allen screw 3. M6x50 Allen screw Step Procedure Step Procedure Push the alternator into the lug of the al- Attach the tension bar finger-tight to the ternator bracket and fix initially finger-tight alternator bracket using 2 M8x20 hex.
  • Page 79 BRP-Powertrain MAINTENANCE MANUAL Step Procedure Adjust the pulley tension and tighten M10 and M8 hex. screws. Tightening torque M10: 40 Nm (354 in.lb.) Tightening torque M8: 22 Nm (194.7 in.lb.) See the most recent Line Maintenance Manual for the respective engine type. FINISHING WORK - Install the propeller.
  • Page 80 BRP-Powertrain MAINTENANCE MANUAL NOTES 24-30-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 10 July 01/2012...
  • Page 81 BRP-Powertrain MAINTENANCE MANUAL Chapter: 37-00-00 VACUUM SYSTEM Introduction This section describes the vacuum system of the ROTAX 912 i series engine. The description is divided into sub-regions and explanations of system functions. Subject Section 1. Introduction Chapter 37-00-00 2. Vacuum pump...
  • Page 82 BRP-Powertrain MAINTENANCE MANUAL NOTES 37-00-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 2 July 01/2012...
  • Page 83 Chapter: 37-10-00 VACUUM PUMP Introduction This section describes the system, the removal and the installation of the vacuum pump assembly of the ROTAX 912 i Series engine. The descrip- tion is divided into sub-sections and explanations of system functions. Subject Section 1.
  • Page 84 BRP-Powertrain MAINTENANCE MANUAL Location on the engine 37-10-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 2 July 01/2012...
  • Page 85 BRP-Powertrain MAINTENANCE MANUAL Chapter: 37-10-00 VACUUM PUMP SPECIAL TOOLS Description Part number Insertion jig assy. 276332 Retaining tool 242660 Puller assy. 876489 Press-in mushroom 877597 Press-in mushroom 877595 Insertion jig assy. 877276 SERVICE PRODUCTS Description Part number Engine oil n.a. LOCTITE 243 897651 LOCTITE 648...
  • Page 86 BRP-Powertrain MAINTENANCE MANUAL Vacuum pump 37-10-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 4 July 01/2012...
  • Page 87 BRP-Powertrain MAINTENANCE MANUAL SYSTEM DESCRIPTION NOTICE WARNUNG The vacuum pump should be considered an accessory which is used to drive inertia instru- Follow the vacuum pump manufacturer's in- ments installed in the aircraft. structions for maintenance, inspection and re- There is the option of installing a vacuum pump. pair.
  • Page 88 BRP-Powertrain MAINTENANCE MANUAL Fig. 4 Step Procedure Fix the drive sleeve with retaining tool part no. 242660. Loosen the M8x16 Allen screw and remo- ve the vacuum pump gear with the drive sleeve. NOTICE WARNUNG The M8 fastening screw for the vacuum pump gear is 16 mm (0.63 in.) long and has a low screw head in the governor drive.
  • Page 89 BRP-Powertrain MAINTENANCE MANUAL INSPECTION BALL BEARING - INSTALLATION DRIVE SLEEVE - INSPECTION Step Procedure Apply the puller part no. 876489 on the Step Procedure vacuum pump side. Check the gear-tooth system of the drive Insert the press-in mushroom part no. sleeve for damage.
  • Page 90 BRP-Powertrain MAINTENANCE MANUAL Fig. 9 Fig. 11 1. M5x12 countersunk 2. Retaining washer screw 1. Retaining tool part no. 242660 2. Drive sleeve OIL SEAL - INSTALLATION 3. M8x16 Allen screw 4. Vacuum pump gear Step Procedure VACUUM PUMP - INSTALLATION Press in a new oil seal with insertion jig part no.
  • Page 91 BRP-Powertrain MAINTENANCE MANUAL FINISHING WORK Step Procedure Position the vacuum pump including the - Install the propeller gearbox, see section 72- gasket and the attachment flange on the 10-00. crankcase. Screw 4 M6 hex. nuts including lock was- hers onto M6 studs and tighten them. Tightening torque 25 Nm (18.44 ft.lb.) Fig.
  • Page 92 BRP-Powertrain MAINTENANCE MANUAL NOTES 37-10-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 10 July 01/2012...
  • Page 93 BRP-Powertrain MAINTENANCE MANUAL Chapter: 61-00-00 PROPELLER Introduction This section describes the maintenance of the ROTAX 912 i series pro- peller. The description is divided into sub-regions and explanations of system functions. Subject Section 1. Introduction Chapter 61-00-00 2. Governor Chapter 61-20-00...
  • Page 94 BRP-Powertrain MAINTENANCE MANUAL NOTES 61-00-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 2 July 01/2012...
  • Page 95 Chapter: 61-20-00 GOVERNOR Introduction This section describes the system, the removal and the installation of the governor assembly of the ROTAX 912 i Series engine. The description is divided into sub-regions and explanations of system functions. Subject Section 1. Introduction Page 1 2.
  • Page 96 BRP-Powertrain MAINTENANCE MANUAL Location on the engine 61-20-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 2 July 01/2012...
  • Page 97 BRP-Powertrain MAINTENANCE MANUAL Chapter: 61-20-00 GOVERNOR SPECIAL TOOLS Description Part number Puller 876489 Extractor 877615 Press-in mushroom 877590 Press-in mushroom 877595 Press-in mushroom 877597 Insertion jig assy. 276332 Retaining device 242660 SERVICE PRODUCTS Description Part number LOCTITE 243 897651 LOCTITE 648 899788 Effectivity: 912 i Series 61-20-00...
  • Page 98 BRP-Powertrain MAINTENANCE MANUAL Hydraulic governor 61-20-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 4 July 01/2012...
  • Page 99 BRP-Powertrain MAINTENANCE MANUAL SYSTEM DESCRIPTION - Carry out engine test run to check proper functioning of the governor. See section 71- For operation with a hydraulic constant-speed 00-00. propeller on version 3 of the 912 i Series engine, a hydraulic governor can be attached to control NOTICE WARNUNG the propeller.
  • Page 100 BRP-Powertrain MAINTENANCE MANUAL GOVERNOR FLANGE - REMOVAL Fig. 3 Step Procedure Loosen M10x1x19 banjo bolts with gasket rings on both sides of the governor flange and oil pump housing and remove the oil line. Loosen 4 M6x20 Allen screws and 2 M6x16 Allen screws for the flange fasten- ing of the oil feed line.
  • Page 101 BRP-Powertrain MAINTENANCE MANUAL Fig. 6 Fig. 4 1. Insertion jig part no. 276332 1. Retaining tool part no. 242660 2. Distance sleeve 3. M8x16 Allen screw 4. Vacuum pump gear Step Procedure Loosen the M5x12 countersunk screw with retaining washer for the ball bearing fastening.
  • Page 102 BRP-Powertrain MAINTENANCE MANUAL ROLLER BEARING VERSION 2 - REMOVAL See section 72-10-00 propeller gearbox. ROLLER BEARING VERSION 3 - REMOVAL See section 72-10-00 propeller gearbox. Effectivity: 912 i Series 61-20-00 Edition 1/Rev. 2 Page 8 July 01/2014...
  • Page 103 BRP-Powertrain MAINTENANCE MANUAL INSPECTION Fig. 8 GOVERNOR DRIVE CHECK Preparation - General visual inspection. See relevant Main- tenance Manual Line for the 912 i Series engine type. - Clean all parts carefully. NOTICE WARNUNG The M8 fastening screw for the vacuum pump gear is 16 mm long and has a flat screw head for the governor drive, but only 14 mm long and 1.
  • Page 104 BRP-Powertrain MAINTENANCE MANUAL WEAR LIMITS Fig. 10 07454 Propeller gearbox Current measurement Tolerance Tolerance Measure- value limit limit Description ment 100 % 50 % Propeller shaft dia. GB03 31.470 mm 31.481 mm 31.460 mm 31.465 mm actual 35 mm 1.2390 in. 1.2394 in.
  • Page 105 BRP-Powertrain MAINTENANCE MANUAL INSTALLATION Step Procedure GOVERNOR DRIVE - INSTALLATION The needle sleeve is pressed in as far as it will go by turning the hex. screw clock- wise. NOTICE WARNUNG The flange (oil feed line) must not be installed BALL BEARING - INSTALLATION tilted and the O-ring must not be caught.
  • Page 106 BRP-Powertrain MAINTENANCE MANUAL Fig. 13 GOVERNOR FLANGE - INSTALLATION Step Procedure Install the governor flange including the distance sleeve in the crankcase with a new 32x4 O-ring. Place one 7x2 O-ring each in the flange (oil feed line) and governor flange and hold them in position with a little grease.
  • Page 107 BRP-Powertrain MAINTENANCE MANUAL Fig. 15 1. Governor flange 2. M6x20 Allen screw 1. Governor flange 2. M10x1 banjo bolt 3. M6x16 Allen screw 3. A10x14 gasket ring 4. Governor pressure oil line assy. Step Procedure 5. 8.4 distance sleeve 6. 8/M8 cable clamp Install the propeller gearbox.
  • Page 108 BRP-Powertrain MAINTENANCE MANUAL GOVERNOR INSTALLATION Various screws and nuts are required, depen- ding on the manufacturer of the governor. See the current edition of SB-912-052 "Installation/ use of governors". Governors manufactured by NOTE: McCAULEY and WOODWARD can- not be installed in the 912 i Series en- gine type due to their length.
  • Page 109 BRP-Powertrain MAINTENANCE MANUAL Chapter: 71-00-00 POWER PLANT Introduction This section describes installation and removal during maintenance or overhauling of the ROTAX 912 i Series engine. Subject Page 1. Introduction Page 1 2. Special tools Page 3 3. Installation checklist Page 5 4.
  • Page 110 BRP-Powertrain MAINTENANCE MANUAL NOTES 71-00-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 2 July 01/2012...
  • Page 111 BRP-Powertrain MAINTENANCE MANUAL Chapter: 71-00-00 POWER PLANT SPECIAL TOOLS Description Part no. Engine lifting kit assy. 876040 Effectivity: 912 i Series 71-00-00 Edition 1/Rev. 2 Page 3 July 01/2014...
  • Page 112 BRP-Powertrain MAINTENANCE MANUAL Power plant 71-00-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 4 July 01/2012...
  • Page 113 BRP-Powertrain MAINTENANCE MANUAL INSTALLATION CHECKLIST The following installation checklist must be copied and filled in during power plant/engine installation. Installation checklist for power plant assy./engine 912 iSc Aircraft Type Serial number Registration number Manufacturer Engine Type Serial number FUSE BOX serial number ECU part no.
  • Page 114 BRP-Powertrain MAINTENANCE MANUAL Installation-related point Remark Control unit (ECU) connections checked for secure connection. Connector lock! See also section 71-00-00 Power plant. Laying of wiring harness checked. Grounding cable checked according to aircraft manu- facturer's specifications. Allocation checked. See documentation of aircraft manufacturer. Fuel pump connection checked.
  • Page 115 BRP-Powertrain MAINTENANCE MANUAL GENERAL NOTE After the engine has been unpacked, carry out the following steps to check the state of delivery: DELIVERY OF THE ENGINE Step Procedure Delivery and handling of the engine and assem- Check that the serial number and engine blies type description on the type plate match - When the engine is delivered, check that the...
  • Page 116 BRP-Powertrain MAINTENANCE MANUAL ENGINE PRESERVATION - Visual inspection for possible corrosion on gear set, propeller shaft, clutch, crankshaft, Storage and preservation requirements for a new camshaft, conrod, piston rings and the valves engine If there is any corrosion of the compo- NOTE: The manufacturer BRP Powertrain guarantees nents, the engine must be sent to an...
  • Page 117 MAINTENANCE MANUAL RETURN TO SERVICE SYSTEM DESCRIPTION DESCRIPTION OF DESIGN Return to service A ROTAX 912 i Series engine consists basically WARNING WARNUNG of several main components and add-on assem- blies, which are described in more detail in the Non-compliance can result in serious injuries or Operators Manual (section 1).
  • Page 118 BRP-Powertrain MAINTENANCE MANUAL TYPE DESCRIPTION OPERATING FLUIDS/CAPACITIES e.g. ROTAX 912 i Sc 3 See the current 912 i Series Operators Manual, "Operating fluids". The type description is composed as NOTE: follows. WEIGHTS See the current 912 i Series Operators Manual, "Technical data".
  • Page 119 BRP-Powertrain MAINTENANCE MANUAL PART NO. Firing order 1-4-2-3 Spark plugs 12 mm, DCPR8E The part number consists of a simple six-digit number block. Electrode gap See section 74-00-00 This number block is a consecutive number. Integrated generator Permanent magnet single- phase generator e.g.
  • Page 120 BRP-Powertrain MAINTENANCE MANUAL Components, engine views Fig. 1 1. Engine number 2. Propeller flange 3. Propeller gearbox 4. Ignition housing 5. Engine suspension frame 6. Water pump housing 7. Muffler assy. (optional) 71-00-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 12 July 01/2012...
  • Page 121 BRP-Powertrain MAINTENANCE MANUAL Fig. 2 8. Oil pump housing 9. Oil filter 10. Fuel rail left/right 11. Fuel hose assy. 19. Connection for oil feed line 20. Connection for oil return line Effectivity: 912 i Series 71-00-00 Edition 1/Rev. 0 Page 13 July 01/2012...
  • Page 122 BRP-Powertrain MAINTENANCE MANUAL Fig. 3 12. Intake manifold, left (cyl. 1/3), right 13. Expansion tank assy. 14. Airbox 15. Electric starter assy. (cyl. 2/4) 16. Fuel pressure regulator 17. Fuel pump module assy. 18. Oil tank assy. 21. Connection for fuel return line 22.
  • Page 123 BRP-Powertrain MAINTENANCE MANUAL MAINTENANCE Fig. 4 As well as the maintenance and special checks, see the relevant Maintenance Manual Line for the respective 912 i Series engine type. REMOVAL POWER PLANT - REMOVAL Preparation To remove the engine, carry out the following steps.
  • Page 124 BRP-Powertrain MAINTENANCE MANUAL Fuse box (FUSE BOX) Step Procedure See section 76-50-00. Mark the controller connector before de- taching. Step Procedure Push in the tab on the top of the connector Loosen M5 hex. nut from the earthing ca- and at the same time pull the connector ble on controller A.
  • Page 125 BRP-Powertrain MAINTENANCE MANUAL Fig. 10 Step Procedure Detach the connectors (Fuel pump 1, Fuel pump 2) from the fuel pumps. NOTE: First lift one side with a screwdriver, fix the tab and then lift the lower tab with the screwdriver and pull out the connector.
  • Page 126 BRP-Powertrain MAINTENANCE MANUAL Control unit (ECU) Fig. 15 See also section 76-10-00 Control unit (ECU). Step Procedure Detach the couplers (ECU LANE A1, ECU LANE A2 and ECU LANE B). Fig. 14 1. Lock REMOVAL OF THE POWER PLANT FROM THE AIRCRAFT Lift the engine from the aircraft using a crane or similar lifting gear.
  • Page 127 BRP-Powertrain MAINTENANCE MANUAL Step Procedure Fasten the straps properly to the suspen- sion points and to the lifting gear/crane. Fig. 16 1. Suspension points Step Procedure Slowly tauten the straps by moving the crane upwards. Loosen the screw connections between the engine suspension and the fire wall.
  • Page 128 BRP-Powertrain MAINTENANCE MANUAL INSTALLATION ENGINE - INSTALLATION NOTICE WARNUNG As well as the instructions given, the installation Danger of damage to the power plant and air- graphics with the major dimensions are useful. craft! WARNING All precautions specified by the aircraft manu- WARNUNG facturer in its documentation must be followed! Danger of injury due to falling parts!
  • Page 129 BRP-Powertrain MAINTENANCE MANUAL CONNECTING THE LINES Step Procedure Install the screw connections of the engi- Connect all the supply lines between the engine ne suspension to the fire wall according to and the aircraft. the aircraft manufacturer's instructions The supply lines are connected and disconnec- and tighten them diagonally from each ted the same way.
  • Page 130 BRP-Powertrain MAINTENANCE MANUAL REMOVAL NOTICE WARNUNG REMOVAL OF THE ENGINE SUSPENSION FRAME On the left-hand side (cylinders 2/4), thrust was- hers can be built in for tension-free assembly. WARNING Do not lose them! WARNUNG Fig. 19 Danger of severe burns and scalds! Always allow the engine to cool down to ambient temperature before starting any work.
  • Page 131 BRP-Powertrain MAINTENANCE MANUAL Fig. 21 INSPECTION ENGINE SUSPENSION FRAME CHECK Step Procedure All components must be visually in- spected. Detailed visual inspection of the engi- NOTE: ne suspension frame in the vicinity of all welded connections between the tube and the struts. Fig.
  • Page 132 BRP-Powertrain MAINTENANCE MANUAL INSTALLATION INSTALLATION OF THE ENGINE SUSPEN- SION FRAME NOTICE WARNUNG The engine suspension frame must be installed in a tension-free manner. Space out the engine suspension frame with thrust washers. The M10x110 Allen screws must con- NOTE: form to strength class 10.9.
  • Page 133 BRP-Powertrain MAINTENANCE MANUAL Chapter: 72-00-00 ENGINE Introduction This section describes the maintenance of the ROTAX 912 i Series engine. The description is divided into sub-sections and explanations of system functions. Subject Section 1. Introduction Chapter 72-00-00 2. System description Page 3 3.
  • Page 134 BRP-Powertrain MAINTENANCE MANUAL Engine 72-00-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 2 July 01/2012...
  • Page 135 BRP-Powertrain MAINTENANCE MANUAL SYSTEM DESCRIPTION The 912 i Series engine is a 4-cylinder, four- stroke, horizontally opposed engine with mani- fold injection. The 912 i Series has liquid cooled cylinder heads and ram air cooled cylinders; this engine also has a fully redundant, electronic engine management system (EMS) including fuel injec- tion, map-controlled ignition etc.
  • Page 136 BRP-Powertrain MAINTENANCE MANUAL NOTES 72-00-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 4 July 01/2012...
  • Page 137 BRP-Rotax MAINTENANCE MANUAL Chapter: 72-10-00 PROPELLER GEARBOX Introduction This section describes the maintenance of the ROTAX 912 i Series gear- box. The description is divided into sub-regions and explanations of sys- tem functions. Subject Page 1. Introduction Page 1 2. Special tools Page 3 3.
  • Page 138 BRP-Rotax MAINTENANCE MANUAL Location on the engine 72-10-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 2 July 01/2012...
  • Page 139 BRP-Rotax MAINTENANCE MANUAL Chapter: 72-10-00 PROPELLER GEARBOX SPECIAL TOOLS Description Part no. Hot air gun n.a. Insert SW 41 877445 Puller 877660 Pushing jig assy. 877540 Mounting yoke 876885 Fixture n.a. Circlip pliers n.a. Extractor 877615 Press-out mushroom (version 3) 877600 Press-out mushroom (version 2) 877605...
  • Page 140 BRP-Rotax MAINTENANCE MANUAL Components 72-10-00 Effectivity: 912 i Series Edition 1/Rev. 3 Page 4 July 01/2018...
  • Page 141 BRP-Rotax MAINTENANCE MANUAL SYSTEM DESCRIPTION MAINTENANCE The propeller shaft is driven by the crankshaft by As well as the maintenance and special checks, means of a linear helical gear unit. Gear ratio see the relevant Maintenance Manual Line for Crankshaft : propeller shaft 2.43 : 1. the respective 912 i Series engine type.
  • Page 142 BRP-Rotax MAINTENANCE MANUAL If desired, the optimised special tool NOTE: Step Procedure part no. 877540 can be used to re- Install puller part no. 877660 onto the two move the propeller gearbox. M8 threaded bolts of the gear cover. Fig. 3. The entire propeller gearbox can now be Step Procedure...
  • Page 143 BRP-Powertrain MAINTENANCE MANUAL DISASSEMBLY Step Procedure DISASSEMBLY OF THE PROPELLER Heat the M30x1.5 hex. nut with the hot air gun (100-120 °C) (212 °F-248 °F). GEARBOX Loosen M30x1.5 hex. nut with wrench Fig. socket SW 41 part no. 877445. NOTE: The hex.
  • Page 144 BRP-Rotax MAINTENANCE MANUAL Fig. 8 Fig. 6 1. Bearing bushing 2. Propeller shaft 1. Clutch assy. 2. Disc springs Step Procedure 3. Step collar 4. Compensating shim Remove the clutch assy., 80x35x3 disc 5. Distance sleeves spring, step collar, 35.4/43/1 compensat- ing shim REMOVAL OF THE PROPELLER SHAFT and 35.2/42/8 distance sleeve.
  • Page 145 BRP-Powertrain MAINTENANCE MANUAL Alternatively, the hand press can also NOTE: Step Procedure be used to press out the propeller Loosen 4 M7x16 hex. screws with wash- shaft. ers from the gearbox housing. Step Procedure Heat the gearbox housing about 100 to Screw the extractor onto the gearbox 120 °C (212 °F - 248 °F) and press the housing with six M6 Allen screws and...
  • Page 146 BRP-Rotax MAINTENANCE MANUAL REMOVAL OF THE OIL SPRAY NOZZLE Step Procedure Place the pull-in spindle into the extractor Step Procedure and through the crankcase. Loosen the banjo bolt M8x1with Torx T40. On the rear side of the crankcase, push Fig. 12 the pullout plate part no.
  • Page 147 BRP-Powertrain MAINTENANCE MANUAL REMOVAL OF THE ROLLER BEARING - Fig. 15 VERSION 3 Preparation - The propeller gearbox must be removed so that the roller bearing can be removed. - Remove the governor flange. NOTICE WARNUNG The pressing out process for version 3 with the hydraulic governor is different from that for ver- sions 2 and 4.
  • Page 148 BRP-Rotax MAINTENANCE MANUAL INSPECTION Fig. 17 PROPELLER GEARBOX SINGLE PARTS CHECK Preparation - Clean all parts carefully. GEAR COVER ASSY. CHECK Step Procedure Inspect the gear cover for cracks using a dye penetrant method or magnetic parti- cle method. NOTE: Only carry out in the case of ground contact! 1.
  • Page 149 BRP-Powertrain MAINTENANCE MANUAL PROPELLER SHAFT - INSPECTION Fig. 20 NOTICE WARNUNG The entire propeller shaft including fastening bores must be free from corrosion; there must be no fretting corrosion at the bearing points ei- ther. Step Procedure Measure both bearing points. See also section 72-10-00 Wear limits.
  • Page 150 BRP-Rotax MAINTENANCE MANUAL THRUST WASHER CHECK, BEARING BUSHING CHECK NOTICE WARNUNG Step Procedure To apply the protective paint, carefully cover the Measure the thickness of the plastic thrust washer between the gear set and the flange surface, fastening bores and the propel- drive gear;...
  • Page 151 BRP-Powertrain MAINTENANCE MANUAL If the gearbox is installed, it is also Fig. 23 NOTE: possible to check the gear set using an endoscope. This must be done in such a manner that an exact assess- ment of the tooth flanks is possible and requires experience.
  • Page 152 BRP-Rotax MAINTENANCE MANUAL PITTING, GENERAL INFORMATION Conclusion: These pits are not important for safe operation. When pitting occurs it is necessary to NOTE: distinguish between tolerable initial The gear set can still be used. pitting and flake pitting. To make the The illustrations are sometimes not NOTE: assessment easier for you, see the...
  • Page 153 BRP-Powertrain MAINTENANCE MANUAL Fig. 26 NOTICE WARNUNG The whole gear set must always be replaced. Dog hubs or drive gears must not be replaced individually. Fig. 27 Magnification: approx. 1.5x DESTRUCTIVE PITTING Fig. 27 Fig. 28. Features: Extensive flank fractures, generally occurring as zones of pitting.
  • Page 154 BRP-Rotax MAINTENANCE MANUAL FLAKE PITTING (LARGE-AREA FLANK Fig. 29 FRACTURES) Fig. 29 Fig. 30. Features: A large-area, triangular flank fracture emanating from a micropitting zone or a fine line of pits in the tooth dedendum. The fracture area has a rel- atively constant depth.
  • Page 155 BRP-Rotax MAINTENANCE MANUAL NOTES Effectivity: 912 i Series 72-10-00 Edition 1/Rev. 3 Page 19 July 01/2018...
  • Page 156 BRP-Powertrain MAINTENANCE MANUAL WEAR LIMITS Fig. 31 72-10-00 Effectivity: 912 i Series Edition 1/Rev. 3 Page 20 July 01/2018...
  • Page 157 BRP-Powertrain MAINTENANCE MANUAL Current measurement Tolerance Tolerance Measure- value limit limit Description ments 100 % 50 % Propeller gearbox 1) Bearing bushing in gear cover Bore GB01 28.03 mm 28.04 mm 28.10 mm 28.07 mm current 1.1035 in. 1.1039 in. 1.1063 in.
  • Page 158 BRP-Powertrain MAINTENANCE MANUAL PROPELLER GEARBOX Fig. 32 09581 Current measurement Tolerance Tolerance Measure- value limit limit Description ments 100 % 50 % 4) Gear profile Crankshaft CS07 0.95 mm 1.00 mm 0.80 mm 0.88 mm current 0.0374 in. 0.0374 in. 0.0315 in.
  • Page 159 BRP-Powertrain MAINTENANCE MANUAL Current measurement Tolerance Tolerance Measure- value limit limit Description ments 100 % 50 % 6) Overload clutch Axial gap GB07 1.0 mm 1.2 mm 0.5 mm 0.8 mm current 0.039 in. 0.047 in. 0.020 in. 0.030 in. replaced Clutch/dog hub GB08 0.0 mm...
  • Page 160 BRP-Rotax MAINTENANCE MANUAL ASSEMBLY INSTALLATION OF BALL BEARING Preparation Step Procedure Press the oil seal into the gearbox hous- WARNING WARNUNG ing from the inside using insertion jig part no. 876518. Danger of severe burns and scalds! Wear heat- NOTE: Lubricate sealing lips with en- resistant gloves! gine oil.
  • Page 161 BRP-Powertrain MAINTENANCE MANUAL Propeller gearbox with oil spray nozzle: Fig. 36 Fig. 35 1. M7x16 hex. screw 2. 7.2/18.8/3 washer 3. Ball bearing 6207 E 4. 36/50/5.5 spacer ring THNC3 1. Gearbox housing 2. Oil seal 5. Oil seal AS 40x55x7 FPM 3.
  • Page 162 BRP-Rotax MAINTENANCE MANUAL Fig. 37 Fig. 39 1. Bearing bushing 2. Propeller shaft Propeller gearbox with oil spray nozzle: NOTICE WARNUNG Fig. 38 The thrust washer must be replaced every re- pair. Step Procedure Push on the gear (propeller shaft). Lubricate the plastic 33.2/51/1.2 thrust washer on both sides with LITHIUM- BASE GREASE and push it on along with...
  • Page 163 BRP-Powertrain MAINTENANCE MANUAL ADJUSTMENT OF THE DISC SPRING Step Procedure PRETENSION Place the whole gearbox in a suitable fix- ture. To make adjustment easier, it can be NOTE: spaced out until the contact face for Press down the gear (propeller shaft) with the ring halves aligns with the upper a mounting yoke part no.
  • Page 164 BRP-Rotax MAINTENANCE MANUAL Fig. 43 Fig. 45 1. Oil inlet flange 2. O-ring 1. Extractor part no. 877615 2. Press-in mushroom 3. M6 threaded bores part no. 877590 3. Roller bearing Fig. 44 Fig. 46 1. 52x2 retaining ring 1. Governor flange 2.
  • Page 165 BRP-Powertrain MAINTENANCE MANUAL Fig. 47 PROPELLER GEARBOX - INSTALLATION Preparation NOTICE WARNUNG No hammering or pressing! The drive gear must only be pushed on manual- NOTICE WARNUNG Ensure that the friction washer is in the correct installation position. 1. Retaining tool part no. 2.
  • Page 166 BRP-Rotax MAINTENANCE MANUAL Fig. 48 Fig. 49 1. 6x20 dowel pins NOTICE WARNUNG 09588 If excessive installation force is used, the bear- 1. Crankshaft (power take off side) 2. Drive gear ing or vacuum pump gear can be damaged. 3. Crankshaft 4.
  • Page 167 BRP-Powertrain MAINTENANCE MANUAL Fig. 50 1. M8 Allen screw 2. M6 Allen screw Step Procedure Tighten 2 M8x45 Allen screws and 8 M6x45 Allen screws with washers 6.4 di- agonally from each other. Tightening torque M6: 10 Nm (89 in.lb.) Tightening torque M8: 25 Nm (19 ft.lb.) Inspect the run-out.
  • Page 168 BRP-Rotax MAINTENANCE MANUAL NOTES 72-10-00 Effectivity: 912 i Series Edition 1/Rev. 3 Page 32 July 01/2018...
  • Page 169 BRP-Powertrain MAINTENANCE MANUAL Chapter: 72-20-00 ENGINE BLOCK Introduction This section describes the maintenance of the ROTAX 912 i Series engine block. The description is divided into sub-section and explana- tions of system functions. Subject Page 1. Introduction Page 1 2. Special tools Page 3 3.
  • Page 170 BRP-Powertrain MAINTENANCE MANUAL NOTES 72-20-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 2 July 01/2012...
  • Page 171 BRP-Powertrain MAINTENANCE MANUAL Chapter: 72-20-00 ENGINE BLOCK SPECIAL TOOLS Description Part no. Hot air gun n.a. Puller 877375 Seeger ring pliers n.a. Free wheel gear axial clearance measuring fix- n.a. ture 38x20 insert for SW32 hex. nut, magneto side 876070 crankshaft A 20x12.5 reducing socket 877460...
  • Page 172 BRP-Powertrain MAINTENANCE MANUAL Engine block 72-20-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 4 July 01/2012...
  • Page 173 BRP-Powertrain MAINTENANCE MANUAL GENERAL NOTE SPRAG CLUTCH - REMOVAL This section only describes work relating directly Preparation to repairing the engine block and its assemblies. Note the cross-references to maintenance work NOTICE WARNUNG and work on other assemblies which is neces- sary when working on the engine block.
  • Page 174 BRP-Powertrain MAINTENANCE MANUAL Fig. 4 Step Procedure Heat the hex. collar nut about 100 °C to 120 °C (212 °F-248 °F) using a hot air gun. Loosen the M32x1.5 hex. collar nut from the crankshaft with a SW 38 socket part no.
  • Page 175 BRP-Powertrain MAINTENANCE MANUAL that all the parts can be laid out and allocated INSPECTION according to their installation position. SPRAG CLUTCH HOUSING Step Procedure SINGLE PARTS CHECK Remove the circlip from the sprag clutch Preparation housing. - Clean all parts carefully. See also chapter 05- Compress the Seeger ring slightly using 00-00 "Procedures".
  • Page 176 BRP-Powertrain MAINTENANCE MANUAL Fig. 9 Step Procedure Check the sprag clutch engagement face on the free wheel gear. Check the cone surface. Fig. 11 1. Crankshaft 2. Crankshaft bore (oil duct) SPRAG CLUTCH CHECK Step Procedure 1. Sprag clutch engagement 2.
  • Page 177 BRP-Powertrain MAINTENANCE MANUAL ASSEMBLY Fig. 14 ASSEMBLY OF THE SPRAG CLUTCH HOUSING Step Procedure Clean the cone of the sprag clutch hous- ing with a cloth. Apply KLUEBER ISOFLEX TOPAS to the spear body. Fig. 13 1. Sprag clutch 2. Seeger ring 3.
  • Page 178 BRP-Powertrain MAINTENANCE MANUAL NOTES 72-20-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 10 July 01/2012...
  • Page 179 BRP-Powertrain MAINTENANCE MANUAL INSTALLATION Fig. 16 Preparation - Fix the crankshaft into place. See relevant Maintenance Manual Line for the 912 i Series engine type INSTALLATION OF THE SPRAG CLUTCH HOUSING NOTICE WARNUNG Approx. 2 to 3 mm on the underside of the sprag clutch housing must not be lubricated with LOC- 1.
  • Page 180 BRP-Powertrain MAINTENANCE MANUAL Fig. 18 MEASURING THE AXIAL CLEARANCE OF THE FREE WHEEL GEAR im Eingriff / frei drehbar / engaged freely turning Fig. NOTICE WARNUNG If there is no or too little axial clearance, the sprag clutch may not be release and the electric starter may be damaged.
  • Page 181 BRP-Powertrain MAINTENANCE MANUAL ES10 07506 Fig. 20 WEAR LIMITS Free wheel gear Toleran- Current measure- Tolerance ment value limit Description Measurements limit 100 % 50 % Axial clearance ES10 0.5 mm 1.1 mm 0.2 mm 0.4 mm current 0.020 in. 0.043 in.
  • Page 182 BRP-Powertrain MAINTENANCE MANUAL NOTES 72-20-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 14 July 01/2012...
  • Page 183 BRP-Powertrain MAINTENANCE MANUAL Chapter: 72-30-00 CYLINDER HEAD Introduction This section describes the maintenance of the ROTAX 912 i Series cylin- der head. The description is divided into sub-sections and explanations of system functions. Subject Page 1. Introduction Page 1 2. Special tools Page 3 3.
  • Page 184 BRP-Powertrain MAINTENANCE MANUAL Location on the engine 72-30-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 2 July 01/2012...
  • Page 185 BRP-Powertrain MAINTENANCE MANUAL Chapter: 72-30-00 CYLINDER HEAD SPECIAL TOOLS Description Part no. Cylinder aligning tool 877262 Measuring fixture (valve spring inspection) n.a. Spring clamp pliers 877840 Valve spring mounting device 877380 Torx T30 ball-head insert 876180 Collet n.a. SERVICE PRODUCTS Description Part no.
  • Page 186 BRP-Powertrain MAINTENANCE MANUAL Cylinder head 72-30-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 4 July 01/2012...
  • Page 187 BRP-Powertrain MAINTENANCE MANUAL SYSTEM DESCRIPTION INSTALLATION OF SURROUNDING AS- SEMBLIES The 912 i Series engine has 4 liquid-cooled cylinder heads. NOTICE WARNUNG SAFETY INFORMATION Use appropriate protective coverings to prevent the ingress of foreign bodies into all dis- WARNING WARNUNG connected lines and connections.
  • Page 188 BRP-Powertrain MAINTENANCE MANUAL Fig. 3 Step Procedure Disconnect the wiring harness from the temperature sensor and remove the tem- perature sensor. To do this, see section 76-70-00 Sensors and actuators. Loosen 4 M6x20 hex./torx collar screws from the intake manifold. Remove the 2 insulating flanges bet- NOTE: ween the intake manifold and the...
  • Page 189 BRP-Powertrain MAINTENANCE MANUAL Fig. 5 NOTICE WARNUNG Do not lose the O-rings! Step Procedure Loosen 2 hex. nuts. Loosen 2 M8 collar cap nuts inside the valve cover (diagonally). Fig. 7 1. M6x20 Allen screw 2. 6.4 washer 3. Coolant elbow 4.
  • Page 190 BRP-Powertrain MAINTENANCE MANUAL If the parts are installed again with the NOTE: same position and allocation as befo- Step Procedure re they were removed, the push-rods Lift the intake manifold with the fuel rail can be reused. The reason for this is slightly and carefully pull the entire cylin- the break-in which takes place on the parts prior to removal.
  • Page 191 BRP-Powertrain MAINTENANCE MANUAL DISASSEMBLY VALVE - REMOVAL DISASSEMBLING THE CYLINDER HEAD Fig. The cylinder head should be disassembled on a NOTICE WARNUNG clean surface. There must be enough space to lay out the removed parts to ensure that all the Before taking out the valves, remove any burrs parts can be laid out and allocated according to on the valve stem to avoid damage to the stem...
  • Page 192 BRP-Powertrain MAINTENANCE MANUAL COOLANT ELBOW INLET - Fig. 12 REMOVAL Step Procedure Heat the coolant elbow with a hot air gun to max. 120 °C. Remove the coolant elbow. Remove adhesive residues in the bore and check the thread. Fig. 11 1.
  • Page 193 BRP-Powertrain MAINTENANCE MANUAL INSPECTION Fig. 13 CYLINDER HEAD SINGLE PARTS CHECK Preparation - Clean all parts carefully. See also section 05- 00-00 Procedures CYLINDER HEAD STUDS CHECK Step Procedure M8x20/23 studs are used to attach the ex- haust manifold. Check that they are securely fitted and undamaged.
  • Page 194 BRP-Powertrain MAINTENANCE MANUAL If the sealing cone of the exhaust ma- NOTE: HARDNESS TEST METHOD: nifold leaks, post-machining is per- missible. If post-machining is neces- NOTICE sary, the cylinder head must be sent WARNUNG to an authorised ROTAX overhauling company. If the engine has been overheated, a hardness Fig.
  • Page 195 BRP-Powertrain MAINTENANCE MANUAL Fig. 18 VALVE CHECK NOTICE WARNUNG Replace the valve if the valve stem is out of spe- cification, is damaged or shows traces of wear. Step Procedure Check the valve visually for damage and wear. Determine the valve stem diameter and check the valve disc for wear.
  • Page 196 BRP-Powertrain MAINTENANCE MANUAL Fig. 21 Step Procedure The 3 retaining grooves on the valve stem must be visually inspected for damage and wear. A new valve cotter must be inserted NOTE: for the wear check. This must have no perceptible backlash. VALVE SEATS CHECK Fig.
  • Page 197 BRP-Powertrain MAINTENANCE MANUAL The valve spring support can be used Fig. 23 NOTE: as an indicator of a malfunction of the valve drive relating to poorly or insuf- ficiently ventilated hydraulic valve tap- pets. In normal conditions, no mea- surable wear can be seen even after a relatively long operating time.
  • Page 198 BRP-Powertrain MAINTENANCE MANUAL Fig. 26 Fig. 27 dim. 06454 1. Push-rod 2. Ball joint 1. Rocker arm 2. Rocker arm shaft 3. Rocker arm bushing 4. Oil ducts 3. Valve guide 4. Ball joint Step Procedure ROCKER ARM BUSHING Check the surface of the rocker arm shaft and the inner diameter of the rocker arm With the rocker arm bushings (plastic bushing), ensure that the plastic bushing is a sliding seat.
  • Page 199 BRP-Powertrain MAINTENANCE MANUAL WEAR LIMITS CH05 CH05 06458 Effectivity: 912 i Series 72-30-00 Edition 1/Rev. 0 Page 17 July 01/2012...
  • Page 200 BRP-Powertrain MAINTENANCE MANUAL 06459 72-30-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 18 July 01/2012...
  • Page 201 BRP-Powertrain MAINTENANCE MANUAL Current measurement Tolerance Tolerance value limit limit Description Measurements 100 % 50 % 1) Cylinder head Diameter Intake CH01 7.006 mm 7.018 mm 7.150 mm 7.084 mm current Valve 0.2758 in. 0.2763 in. 0.2815 in. 0.2789 in. replaced Valve Exhaust...
  • Page 202 BRP-Powertrain MAINTENANCE MANUAL Current measurement Tolerance Tolerance value limit limit Description Measurements 100 % 50 % 3.2) Rocker arm Bore Intake CH05 12.200 mm 12.218 mm 12.290 mm 12.254 mm current for rocker Valve 0.4803 in. 0.4810 in. 0.4839 in. 0.4824 in.
  • Page 203 BRP-Powertrain MAINTENANCE MANUAL ASSEMBLY Step Procedure CYLINDER HEAD - ASSEMBLY Allow the cylinder head to harden for 10 minutes at 100 °C. Preparation NOTE: If the sealing surface of the cylin- - Clean all parts carefully. der has carbon residues, it must be removed carefully.
  • Page 204 BRP-Powertrain MAINTENANCE MANUAL VALVE INSTALLATION Fig. 31 NOTICE WARNUNG Risk of engine damage if damaged parts are in- stalled! All parts must be measured and assessed befo- re installation. All moving parts must be lubricated with engine oil before installation! NOTICE WARNUNG Oil residues up to max.
  • Page 205 BRP-Powertrain MAINTENANCE MANUAL Fig. 34 ROCKER ARM - INSTALLATION NOTICE WARNUNG Do not use force! The rocker arm bearing is a sliding seat. Step Procedure Lubricate the rocker arm shaft (on both sides), rocker arm bore and valve spring support with KLUEBER ISOFLEX TO- PAS.
  • Page 206 BRP-Powertrain MAINTENANCE MANUAL NOTES 72-30-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 24 July 01/2012...
  • Page 207 BRP-Powertrain MAINTENANCE MANUAL The intake manifold with the fuel rail INSTALLATION NOTE: must be raised slightly for part re- CYLINDER HEAD INSTALLATION pairs. Preparation Step Procedure - Clean all parts carefully. Place on the cylinder head until the O-rings of the two oil return tubes rest in - Lightly grease or lubricate O-rings and gas- the crankcase.
  • Page 208 BRP-Powertrain MAINTENANCE MANUAL Fig. 39 Step Procedure Align the second cylinder head on the in- take manifold and fasten it with 2 M6x20 hex./torx collar screws. Tightening torque 10 Nm (88.48 in. lb.). NOTE: This aligns the cylinder heads to ensure a flat support for the in- take manifold.
  • Page 209 BRP-Powertrain MAINTENANCE MANUAL Fig. 42 Fig. 44 1. M6x20 Allen screw 2. 6.4 washer 1. Airbox 2. M6 hex. nut 3. Coolant elbow 4. Elbow flange 3. 6.4 washer - Install the coolant hose as far as the mark on - Install the spark plugs and connect the resi- the coolant elbow.
  • Page 210 BRP-Powertrain MAINTENANCE MANUAL IF BOTH CYLINDER HEADS PER ENGINE Fig. 47 SIDE HAVE BEEN REPAIRED Step Procedure Fasten the cylinder aligning tool part no. 877262 to the intake flange of the cylinder heads with 4 M6x25 Allen screws. NOTE: This aligns the cylinder heads to ensure a flat support for the in- take manifold.
  • Page 211 BRP-Powertrain MAINTENANCE MANUAL FINISHING WORK Step Procedure - Install the coolant hoses to the inlet and outlet elbow. See also section 75-00-00 Cooling Install the 105x2.5 O-ring and the 6.4x1.8 system. O-ring in the valve cover. - Install the intake manifold. See also section Place on the valve cover and fasten it with 73-00-00 Fuel system.
  • Page 212 BRP-Powertrain MAINTENANCE MANUAL NOTES 72-30-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 30 July 01/2012...
  • Page 213 BRP-Powertrain MAINTENANCE MANUAL Chapter: 72-30-10 DISPLACEMENT PARTS Introduction This section describes the maintenance of the ROTAX 912 i Series dis- placement parts. The description is divided into sub-sections and expla- nations of system functions. Subject Page 1. Introduction Page 1 2.
  • Page 214 BRP-Powertrain MAINTENANCE MANUAL 72-30-10 Effectivity: 912 i Series Edition 1/Rev. 0 Page 2 July 01/2012...
  • Page 215 BRP-Powertrain MAINTENANCE MANUAL Chapter: 72-30-10 DISPLACEMENT PARTS SPECIAL TOOLS Description Part no. Piston pin extractor assy. 877091 Piston ring spanner, 84 mm 876967 Monohook circlip remover 976380 Installation tool assy. 877802 SERVICE PRODUCTS Description Part no. KLUEBER ISOFLEX TOPAS NB5051 898351 Engine oil n.a.
  • Page 216 BRP-Powertrain MAINTENANCE MANUAL NOTES 72-30-10 Effectivity: 912 i Series Edition 1/Rev. 0 Page 4 July 01/2012...
  • Page 217 BRP-Powertrain MAINTENANCE MANUAL SYSTEM DESCRIPTION Fig. 1 In the 912 i Series engine, 4 cylinders with "GIL- NISIL"-coated running surfaces are used. The pistons are light alloy full skirt pistons. The piston axle is axially offset by 1 mm (0.03937 in.) with respect to the piston skirt.
  • Page 218 BRP-Powertrain MAINTENANCE MANUAL Fig. 2 Step Procedure Loosen the nut and remove the puller. Re- move the piston and put it down with the corresponding cylinder. REMOVAL OF THE HYDRAULIC VALVE TAPPET Put the hydraulic valve tappet down so NOTE: that it can be installed in the same place when it is reused.
  • Page 219 BRP-Powertrain MAINTENANCE MANUAL Two sizes of pistons are available, red INSPECTION NOTE: and green. The difference is 0.01 mm DISPLACEMENT PARTS - INSPECTION (0.00039 in.). The "red" piston is the smaller one. The nominal size of the pis- Preparation ton is stamped on the piston crown. Oversized pistons are not available.
  • Page 220 BRP-Powertrain MAINTENANCE MANUAL PISTON RINGS - INSPECTION Step Procedure Check the piston pin for traces of wear in Step Procedure the region of the conrod bearing and in Check the cleaned piston rings for piston the region of the piston bearing and mea- ring joint clearance.
  • Page 221 BRP-Powertrain MAINTENANCE MANUAL If the tappet does not rotate, uneven NOTE: wear occurs on the contact face. If there Step Procedure are uneven smooth areas, corroded areas/pitting, the tappet must be repla- Clean the cooling fins of the cylinder and ced.
  • Page 222 BRP-Powertrain MAINTENANCE MANUAL WEAR LIMITS 72-30-10 Effectivity: 912 i Series Edition 1/Rev. 0 Page 10 July 01/2012...
  • Page 223 BRP-Powertrain MAINTENANCE MANUAL Effectivity: 912 i Series 72-30-10 Edition 1/Rev. 2 Page 11 July 01/2014...
  • Page 224 BRP-Powertrain MAINTENANCE MANUAL Current measurement Tolerance Tolerance value limit limit Description Measurements 100 % 50 % 1) Piston Cyl. Cyl. Cyl. Cyl. Piston, red PI01 83.988 mm 84.002 mm 83.890 mm 83.939 mm current 84 mm / 3.3066 in. 3.3072 in. 3.3027 in.
  • Page 225 BRP-Powertrain MAINTENANCE MANUAL Current measurement Tolerance Tolerance value limit limit Description Measurements 100 % 50 % Backlash bet- PI06 0.020 mm 0.055 mm 0.100 mm 0.078 mm current ween piston 0.0008 in. 0.0022 in. 0.0039 in. 0.0032 in. replaced ring groove and oil scra- per ring 3 Piston ring...
  • Page 226 BRP-Powertrain MAINTENANCE MANUAL NOTES 72-30-10 Effectivity: 912 i Series Edition 1/Rev. 0 Page 14 July 01/2012...
  • Page 227 BRP-Powertrain MAINTENANCE MANUAL INSTALLATION Fig. 11 CYLINDER AND PISTON - INSTALLATION Preparation - Clean all parts carefully. - Lightly grease or lubricate press-in parts and gaskets. INSTALLATION OF THE HYDRAULIC VAL- VE TAPPET NOTICE WARNUNG If a hydraulic valve tappet has to be replaced, it must be ensured that a hydraulic valve tappet with a polished cam running surface is used.
  • Page 228 BRP-Powertrain MAINTENANCE MANUAL Fig. 13 72-30-10 Effectivity: 912 i Series Edition 1/Rev. 0 Page 16 July 01/2012...
  • Page 229 BRP-Powertrain MAINTENANCE MANUAL Step Procedure NOTICE WARNUNG Lubricate the piston pin along with the Always use new mono hook circlips. Retaining conrod eye and the piston pin bore with rings which are used or have already been in- KLUEBER ISOFLEX TOPAS Nb5051. stalled have insufficient tangential tension, can Pull in the piston pin with the piston pin NOTE:...
  • Page 230 BRP-Powertrain MAINTENANCE MANUAL Fig. 15 Fig. 16 1. Installation tool 2. Installation sleeve 3. Pistons 1. Mono hook circlip 2. Installation sleeve 3. Installation tool 4. Punch tool assy. 5. Guide tool 6. Groove Step Procedure Place the whole installation tool on the pi- ston.
  • Page 231 BRP-Powertrain MAINTENANCE MANUAL CYLINDER INSTALLATION NOTICE WARNUNG NOTICE WARNUNG Double-check that piston pin circlips are instal- led properly. The suitable piston ring spanner part no. 876967 must be used to avoid ring breakages. Step Procedure Ensure that the piston ring joints are in the spe- Install the 87x2 O-ring on the cylinder cified angle range.
  • Page 232 BRP-Powertrain MAINTENANCE MANUAL NOTES 72-30-10 Effectivity: 912 i Series Edition 1/Rev. 0 Page 20 July 01/2012...
  • Page 233 MAINTENANCE MANUAL Chapter: 73-00-00 FUEL SYSTEM Introduction This section describes the maintenance of the fuel system assembly of the ROTAX 912 i Series engine. The description is divided into sub-sec- tions and explanations of system functions. Subject Section 1. Introduction Chapter 73-00-00 A.
  • Page 234 BRP-Powertrain MAINTENANCE MANUAL NOTES 73-00-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 2 July 01/2012...
  • Page 235 BRP-Powertrain MAINTENANCE MANUAL System description Fig. 1 06293 1. Fuel tank 2,3. Fuel pump 4. Water trap/fine filter 5. Fuel pressure regulator Effectivity: 912 i Series 73-00-00 Edition 1/Rev. 0 Page 3 July 01/2012...
  • Page 236 BRP-Powertrain MAINTENANCE MANUAL SYSTEM DESCRIPTION SAFETY INFORMATION The fuel passes from the tanks via the water trap/ WARNING WARNUNG fine filter to the series-connected electric fuel pumps, from there to the fuel rails, the injection During work on the fuel system there is a risk of valves and the fuel pressure regulator.
  • Page 237 Chapter: 73-10-00 FUEL PUMP AND DISTRIBUTION Introduction This section describes the maintenance of the fuel pump and distribution assembly of the ROTAX 912 i Series engine. The description is divided into sub-sections and explanations of system functions. Subject Page 1. Introduction Page 1 2.
  • Page 238 BRP-Powertrain MAINTENANCE MANUAL Subject Page 8. Assembly Page 25 A. Fuel pump assy. - assembly Page 25 B. Fuel pressure regulator - assembly Page 26 9. Installation Page 27 A. Intake manifold - installation Page 27 B. Left-hand and right-hand fuel rail - installation Page 29 C.
  • Page 239 BRP-Powertrain MAINTENANCE MANUAL Chapter: 73-10-00 FUEL PUMP AND DISTRIBUTION SPECIAL TOOLS Description Part no. Seeger ring pliers n.a. SERVICE PRODUCTS Description Part no. KLUEBER ISOFLEX TOPAS Nb5051 898351 LOCTITE 243 897651 LOCTITE 648 899788 Effectivity: 912 i Series 73-10-00 Edition 1/Rev. 0 Page 3 July 01/2012...
  • Page 240 BRP-Powertrain MAINTENANCE MANUAL Fuel distribution 73-10-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 4 July 01/2012...
  • Page 241 BRP-Powertrain MAINTENANCE MANUAL Fuel distribution 1. Fuel pump assy. 2. Fuel hose assy. 3. Injection valves 4. Right-hand fuel rail 5. Fuel pressure regulator assy. 6. Throttle body 7. Airbox 8. Intake manifold Effectivity: 912 i Series 73-10-00 Edition 1/Rev. 0 Page 5 July 01/2012...
  • Page 242 BRP-Powertrain MAINTENANCE MANUAL SYSTEM DESCRIPTION Fuel pressure regulator The fuel pressure regulator keeps the fuel sys- FUEL PUMP MODULE tem pressure upstream of the injection valves The fuel pump module is available from ROTAX constant relative to the intake manifold pressure on request.
  • Page 243 BRP-Powertrain MAINTENANCE MANUAL Fuel line assy. and fuel rails MAINTENANCE The fuel line assy. from the tank to the fuel As well as the maintenance and special checks, pump, to the fuel rail of cylinders 1 and 3 and see the relevant Maintenance Manual Line for also the fuel return line from the fuel rail for cylin- the respective 912 i Series engine type.
  • Page 244 BRP-Powertrain MAINTENANCE MANUAL FUEL LINE ASSY. - REMOVAL Fig. 3 Step Procedure Drain the fuel. See also section 12-20-00 Planned maintenance. Remove the feed line to fuel rail 1/3 and the return line to fuel rail 2/4 and fuel pres- sure regulator and close them with the ap- propriate caps.
  • Page 245 BRP-Powertrain MAINTENANCE MANUAL Fig. 6 Fig. 4 1. M5x35 Allen screw 2. M5x45 Allen screw 1. Cable ties 2. Hose 3. Temperature sensor Step Procedure Loosen the banjo bolt with gasket ring in the pressure regulator housing. Fig. 5 1. Banjo bolt 2.
  • Page 246 BRP-Powertrain MAINTENANCE MANUAL DISASSEMBLY Fig. 8 FUEL PRESSURE REGULATOR ASSY. - DISASSEMBLY Step Procedure Drain the fuel. See also section 12-20-00 Planned maintenance. Remove the cable ties and pull out the hose. Disconnect the plug connection to the temperature sensor. Fig.
  • Page 247 BRP-Powertrain MAINTENANCE MANUAL FUEL RAIL - REMOVAL Fig. 10 Preparation Drain the fuel. See also section 12-20-00 Planned maintenance. Unscrew the feed line to fuel rail 1/3 and the return line to fuel rail 2/4 and fuel pressure regulator and close them with the appropriate caps.
  • Page 248 BRP-Powertrain MAINTENANCE MANUAL Fig. 12 Labelling diagram 1. M5x12 Allen screw 2. 5.3 washer 3. Heat shield 4. M5x35 Allen screw Step Procedure Step Procedure Use a screwdriver to lever out the spring clip and then Disconnect the injectors. unplug the connector. NOTE: The cables are labelled IN- NOTE: Let the wire clip snap back in J_1 to INJ_8.
  • Page 249 BRP-Powertrain MAINTENANCE MANUAL DISASSEMBLY Step Procedure LEFT-HAND (2/4) AND RIGHT-HAND (1/3) Loosen the two M5x12 Allen screws of the left-hand fuel rail (2/4) attachment and the FUEL RAIL - DISASSEMBLY two M5x12 Allen screws of the right-hand Step Procedure fuel rail (1/3) with the lock washers. Remove the injection valves individually Remove the fuel rail on the left and right from the fuel rail.
  • Page 250 BRP-Powertrain MAINTENANCE MANUAL Fig. 17 Fig. 19 1. M6x14 Allen screw 2. 6.4 washer 1. EGT connector 2. Spring clip 3. 12/M6 cable clamp Step Procedure Step Procedure Loosen the M5x16 Allen screws of the Disconnect the 4 ignition coil connectors double ignition coils with washers.
  • Page 251 BRP-Powertrain MAINTENANCE MANUAL Fig. 21 LEFT-HAND 2/4 INTAKE MANIFOLD - REMOVAL Step Procedure Remove the 1-ear clamps. Fig. 22 1. Double ignition coils 2. Ignition coil connector (coil 1, coil 2, coil 3, coil 4) NOTE: The red cable is positive (+), the red ca- ble with the black dash is negative (-).
  • Page 252 BRP-Powertrain MAINTENANCE MANUAL Fig. 24 Fig. 23 1. Insulating flange Fig. 25 1. Outer screw-fastening 2. Inner screw-fastening Step Procedure Remove the insulating flange of the cylin- 1. Plug part no. 860397 der heads. Close the intake duct using a plug (part no.
  • Page 253 BRP-Powertrain MAINTENANCE MANUAL - For removal and installation of pressure and Step Procedure temperature sensors, see section 76-70-00 Remove the two 1-ear clamps. Sensors and actuators. Remove the airbox. NOTE: The pressure and temperature sensors must only be removed if absolutely Fig.
  • Page 254 BRP-Powertrain MAINTENANCE MANUAL THROTTLE BODY ASSY. Fig. 31 - REMOVAL Preparation - General visual inspection. See relevant Main- tenance Manual Line for the 912 i Series engine type. Step Procedure Remove the throttle body assy. Remove the air filter and air intake hose (delivered by manufacturer) from the throttle body assy.
  • Page 255 BRP-Powertrain MAINTENANCE MANUAL FUEL PUMP ASSY. - REMOVAL NOTE: The position and type of positioning and attachment of the fuel pump depends on Preparation the aircraft type. See aircraft manufactu- rer documentation. - Drain the fuel and coolant. See also section See overview and Fig.
  • Page 256 BRP-Powertrain MAINTENANCE MANUAL Fig. 35 Step Procedure Loosen 4 M5 Allen screws from the cover. Disconnect the fuel inlet and outlet. Disconnect the fuel pumps (main, aux): Lift the latches Unplug the connectors. Fig. 33 1. Connector Step Procedure Remove the fuel pump module from the aircraft according to the aircraft manufac- turer's manual.
  • Page 257 BRP-Powertrain MAINTENANCE MANUAL INSPECTION NOTE: If the screen is dirty, all the prefilters must be checked for function and dirt. FUEL DISTRIBUTION Fig. 38 SINGLE PARTS - CHECK Preparation - Clean all parts carefully. See also section 05- 00-00 Procedures FUEL LINE ASSY.
  • Page 258 BRP-Powertrain MAINTENANCE MANUAL Fig. 40 INJECTION VALVE - INSPECTION Step Procedure Check the injection valves for damage. Scuffing marks (including scratches) on the valves are permissible up to a maximum depth of 0.2 mm (0.0079 in.). All O-rings must be replaced when the in- jection valves are repaired.
  • Page 259 BRP-Powertrain MAINTENANCE MANUAL Fig. 43 AIRBOX - INSPECTION Step Procedure Check the airbox for damage and wear. Check the support plates for damage. Check the connecting pieces for brittle- ness. Check threaded bores for damage. Fig. 45 1. Intake manifold 2.
  • Page 260 BRP-Powertrain MAINTENANCE MANUAL THROTTLE BODY - INSPECTION Step Procedure Ensure that the throttle valve and the NOTICE WARNUNG bowden cable can move freely. Check that the fastening and securing el- Danger of consequent damage to engine! ements are secure. The throttle body must not be post-machined! If the throttle body is damaged or worn, it must be replaced with a new part.
  • Page 261 BRP-Powertrain MAINTENANCE MANUAL CHECK VALVE - INSPECTION ASSEMBLY FUEL PUMP ASSY. - ASSEMBLY Fig. 47. Step Procedure Step Procedure Check the check valves for damage and Fix the fuel pump unit in the housing with wear. 4 M6 hex. nuts. Tightening torque 10 Nm (88.48 in.
  • Page 262 BRP-Powertrain MAINTENANCE MANUAL Fig. 49 Fig. 51 1. Allen screws 2. Intake system 1. 36x1.5 retaining ring 2. Fuel pressure regulator 3. Pressure line 3. Pressure regulator housing FUEL PRESSURE REGULATOR - AIRBOX - ASSEMBLY ASSEMBLY Step Procedure The fuel pressure regulator is assembled and disassembled in the same way.
  • Page 263 BRP-Powertrain MAINTENANCE MANUAL INSTALLATION Step Procedure INTAKE MANIFOLD - INSTALLATION For pressure sensor and temperature sensor installation, see section 76-70-00. Step Procedure Fig. 53 Place the insulating flange on the cylinder heads. Place on the left-hand 2/4 and right-hand 1/3 intake manifolds. Fig.
  • Page 264 BRP-Powertrain MAINTENANCE MANUAL Fig. 55 NOTE: The red cable is positive (+), the red ca- ble with the black dash is negative (-). Double ignition coils are labelled + and -! Step Procedure Plug the connectors into the double igni- tion coils.
  • Page 265 BRP-Powertrain MAINTENANCE MANUAL Step Procedure Step Procedure Connect the connector with the EGT con- Secure the 12/M6 cable clamp with an nector. M6x14 Allen screw and washer with LOCTITE 243. NOTE: Compress the connector with Tightening torque 10 Nm (88.48 in. lb.). the EGT connector so that the spring clip latches in.
  • Page 266 BRP-Powertrain MAINTENANCE MANUAL Fig. 64 Step Procedure Install the injection valves and mufflers. Fig. 62 1. M5x12 Allen screws 2. DIN 128-A5-FST lock 1. Injection valve 2. O-rings washers 3. Fuel rail Fig. 63 Step Procedure Plug in the injectors. NOTE: The cables are labelled INJ_1 to INJ_8.
  • Page 267 BRP-Powertrain MAINTENANCE MANUAL Fig. 68 Fig. 66 1. M5x12 Allen screw 2. 5.3 washer 1. M5x12 Allen screw 2. 5.3 washer 3. Cover 3. Heat shield FUEL PRESSURE REGULATOR ASSY. - Step Procedure INSTALLATION Fix the fuel pressure regulator for cylin- ders 2 and 4 with an M5x35 Allen screw.
  • Page 268 BRP-Powertrain MAINTENANCE MANUAL Fig. 71 Fig. 69 1. M5x35 Allen screw 2. M5x45 Allen screw 1. 94x2.5mm cable ties 2. 60 +/-3mm hose 3. Heat shield 3. Temperature sensor CTS Step Procedure Install the M12x1.5x24 banjo bolt with two THROTTLE BODY ASSY. - A12x18 gasket rings.
  • Page 269 BRP-Powertrain MAINTENANCE MANUAL AIRBOX - INSTALLATION Step Procedure Push the throttle body into the airbox. Se- Step Procedure cure 3 hex./torx collar screws and fixation Install a new 1-ear clamp on the connect- latch with LOCTITE 243. ing piece. Tightening torque 8 Nm (70.78 in. lb.). Insert the airbox in the connecting piece.
  • Page 270 BRP-Powertrain MAINTENANCE MANUAL FUEL LINE ASSY. - INSTALLATION Step Procedure Plug in the wiring harness connector ap- The fuel line is installed and removed in the propriately. See also section 76-50-00 same way. The following should be noted. Wiring harness. NOTICE WARNUNG Fix the plug holder with cable ties.
  • Page 271 BRP-Powertrain MAINTENANCE MANUAL Fig. 80 FINISHING WORK - Fill the fuel and coolant systems. See also section 12-20-00 Planned maintenance. - Install the bowden cable on the throttle body. See section 70-00-00 Standard work on the engine. - Adjustment of the throttle position, sensor position and idle speed.
  • Page 272 BRP-Powertrain MAINTENANCE MANUAL NOTES 73-10-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 36 July 01/2012...
  • Page 273 MAINTENANCE MANUAL Chapter: 74-00-00 IGNITION UNIT Introduction This section describes the maintenance of the ignition unit assembly of the ROTAX 912 i Series engine. The description is divided into sub-sec- tions and explanations of system functions. Subject Section 1. Introduction Chapter 74-00-00 A.
  • Page 274 BRP-Powertrain MAINTENANCE MANUAL Ignition unit 1. Resistance spark plug connector 2. Double ignition coil 3. Ignition cable assy. 4. Fuse box assy. 5. Connector 6. Crankshaft position sensor assy. 7. Stator assy. 74-00-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 2 July 01/2012...
  • Page 275 BRP-Powertrain MAINTENANCE MANUAL SYSTEM DESCRIPTION CONNECTIONS FOR DISPLAY SYSTEMS The ignition unit operates with four double igni- NOTICE WARNUNG tion coils with double ignition. If the LANE selec- tor switch is in the "AUTO" position, the active Follow the instructions in the Installation Manual LANE controls all four double ignition coils which regarding connections for instrumentation.
  • Page 276 BRP-Powertrain MAINTENANCE MANUAL NOTES 74-00-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 4 July 01/2012...
  • Page 277 MAINTENANCE MANUAL Chapter: 74-20-00 DISTRIBUTION Introduction This section describes the maintenance of the ignition unit (distribution) assembly of the ROTAX 912 i Series engine. The description is divided into sub-sections and explanations of system functions. Subject Section 1. Introduction Page 1 2.
  • Page 278 BRP-Powertrain MAINTENANCE MANUAL Distribution 74-20-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 2 July 01/2012...
  • Page 279 BRP-Powertrain MAINTENANCE MANUAL Chapter: 74-20-00 DISTRIBUTION SERVICE PRODUCTS Description Part no. SILIKON heat conduction compound 897186 Effectivity: 912 i Series 74-20-00 Edition 1/Rev. 0 Page 3 July 01/2012...
  • Page 280 BRP-Powertrain MAINTENANCE MANUAL Ignition unit (distribution) 1. Resistance spark plug connector 2. Double ignition coil 3. Ignition cable assy. 4. Fuse box assy. 5. Connector 6. Crankshaft position sensor assy. 7. Stator assy. 74-20-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 4 July 01/2012...
  • Page 281 BRP-Powertrain MAINTENANCE MANUAL Layout plan allocation (cylinder/LANE) Fig. 1 SP 2 SP 2 SP 1 SP 1 SP 4 SP 4 SP 3 SP 3 Regler B Regler B SP 2 SP 2 SP 2 SP 2 LANE B LANE B LANE B LANE B SP 4...
  • Page 282 BRP-Powertrain MAINTENANCE MANUAL NOTES 74-20-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 6 July 01/2012...
  • Page 283 BRP-Powertrain MAINTENANCE MANUAL SYSTEM DESCRIPTION SPARK PLUGS The ignition voltage is distributed directly to the The spark plugs are not shielded but use a cylinders by stationary, electronically controlled resistance type suppressor to prevent interfe- components. rence. The connecting bolt for the high-voltage The ignition voltage is generated by four double ignition cables complies with ISO/DIN standard ignition coils which are situated above the spark...
  • Page 284 BRP-Powertrain MAINTENANCE MANUAL CRANKSHAFT POSITION SENSOR Fig. 2 The crankshaft position sensor sends informa- tion to the control unit about the rotation speed and crankshaft position. MAINTENANCE As well as the maintenance and special checks, see the relevant Maintenance Manual Line for the respective 912 i Series engine type.
  • Page 285 BRP-Powertrain MAINTENANCE MANUAL Step Procedure Step Procedure Carefully pull EGT 1 and EGT 2 (cylinders Unplug the connectors to the double igni- 1 and 2) out of the locking plate. tion coils. Press the metal bracket and unplug the Remove the double ignition coils connectors.
  • Page 286 BRP-Powertrain MAINTENANCE MANUAL Fig. 7 SPARK PLUG - REMOVAL Step Procedure Remove the M14x1.25 SW16 spark plugs anti-clockwise from the corresponding cylinder head. NOTICE WARNUNG Risk of damage to spark plugs! The spark plugs must only be removed with the spark plug wrench! KNOCK SENSOR - REMOVAL See section 76-70-00 Sensors and actuators...
  • Page 287 BRP-Powertrain MAINTENANCE MANUAL INSPECTION Fig. 11 Components can only be replaced, not repaired. If the ignition spark fails, search systematically for the possible cause of the fault. The B.U.D.S. Aircraft diagnostic tool must be used for this. DOUBLE IGNITION COIL ASSY. INSPECTI- Preparation - Carry out a visual inspection.
  • Page 288 BRP-Powertrain MAINTENANCE MANUAL Fig. 12 1. Ignition cable assy. 2. Resistance spark plug connector SPARK PLUG - INSPECTION Step Procedure Check the electrode gap of the spark plug with a feeler gauge and adjust it if neces- sary. See also section 74-20-00 Wear li- mits.
  • Page 289 BRP-Powertrain MAINTENANCE MANUAL WEAR LIMITS 00084 Spark plug Current measure- Tolerance Toleran- ment value limit ce limit Description Measurements 100 % 50 % Electrode gap SP01 0.6 mm 0.7 mm 0.9 mm current 0.0236 in. 0.0276 in. 0.0354 in. replaced 74-20-00 Effectivity: 912 i Series Edition 1/Rev.
  • Page 290 BRP-Powertrain MAINTENANCE MANUAL INSTALLATION RESISTANCE SPARK PLUG CONNEC- TOR AND IGNITION CABLE ASSY. - KNOCK SENSOR - INSTALLATION INSTALLATION See section 76-70-00 Sensors and actuators and section 76-50-00 Wiring harness. NOTICE WARNUNG SPARK PLUG - INSTALLATION Risk of damage to resistance spark plug connector! NOTICE The resistance spark plug connectors must only...
  • Page 291 BRP-Powertrain MAINTENANCE MANUAL Fig. 15 Step Procedure Fix the double ignition coils with M5x16 Allen screws with plug holders and A5 lock washers. Tightening torque 5 Nm (44.25 in. lb.). Fig. 17 1. Ignition cable assy. 2. Cable ties DOUBLE IGNITION COIL - INSTALLATION The double ignition coil is installed and removed in the same way.
  • Page 292 BRP-Powertrain MAINTENANCE MANUAL Step Procedure NOTICE WARNUNG Plug the ignition coil connector into the double ignition coils and press the EGT 90° ignition coil connectors should be attached connector into the plug holder. with cable ties to reduce vibration. NOTE: Check for secure connection.
  • Page 293 BRP-Powertrain MAINTENANCE MANUAL Chapter: 75-00-00 COOLING SYSTEM Introduction This section describes the maintenance of the ROTAX 912 i Series coo- ling system. The description is divided into sub-sections and explanations of system functions. Subject Section 1. Introduction Page 1 2. Special tools Page 3 3.
  • Page 294 BRP-Powertrain MAINTENANCE MANUAL Position on the engine 75-00-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 2 July 01/2012...
  • Page 295 BRP-Powertrain MAINTENANCE MANUAL Chapter: 75-00-00 COOLING SYSTEM SPECIAL TOOLS Description Part no. Spring clamp pliers 877840 Impeller wrench assy. 877295 Insertion jig 876510 Insertion jig 877258 SERVICE PRODUCTS Description Part no. LOCTITE 243 897651 Engine oil n.a. Effectivity: 912 i Series 75-00-00 Edition 1/Rev.
  • Page 296 BRP-Powertrain MAINTENANCE MANUAL Cooling system 75-00-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 4 July 01/2012...
  • Page 297 BRP-Powertrain MAINTENANCE MANUAL SYSTEM DESCRIPTION SAFETY INFORMATION The engine is cooled by liquid-cooled cylinder WARNING WARNUNG heads and ram-air-cooled cylinders. The cooling system of the cylinder heads is a closed cooling Danger of severe burns and scalds! circuit with an expansion tank and overflow Always allow the engine to cool down to ambient bottle.
  • Page 298 BRP-Powertrain MAINTENANCE MANUAL - General visual inspection. See relevant Main- Step Procedure, cyl. 2/4 tenance Manual Line for the 912 i Series Loosen the M6x16 Allen screw of the fuel engine type. line assy. with the lock washer. - Carry out an engine test run. See relevant Loosen the M12x1.5x24 banjo bolt from Maintenance Manual Line for the 912 i Series cyl.
  • Page 299 BRP-Powertrain MAINTENANCE MANUAL Fig. 2(Cyl. 1/3): Preformed hose, cylinders 2 and 4 Fig. 3 1. Spring type hose clip 2. Preformed hose 8. Throttle potentiometer TPS 9. Oil filter 3. Coolant elbow 10. Double ignition coil 11. Fuel inlet Preformed hose, cylinder 1 12.
  • Page 300 BRP-Powertrain MAINTENANCE MANUAL Preformed hose, cylinder 3 WATER PUMP HOUSING - REMOVAL Preparation Fig. 5 - Remove the coolant hose according to the aircraft manufacturer's specifications. NOTICE WARNUNG When removing the preformed hoses, do not damage the coolant elbow on the expansion tank! Step Procedure...
  • Page 301 BRP-Powertrain MAINTENANCE MANUAL Fig. 8 DISASSEMBLY IGNITION HOUSING - DISASSEMBLY Preparation - Remove the ignition housing. See also sec- tion 24-20-00 Internal generator. WATER PUMP SHAFT - REMOVAL Step Procedure Place the ignition cover on a suitable flat surface. Press out the water pump shaft with a suitable tool.
  • Page 302 BRP-Powertrain MAINTENANCE MANUAL Fig. 11 WATER PUMP HOUSING - DISASSEMBLY NOTE: Only remove the coolant elbow when ab- solutely necessary! Step Procedure Mark the position of the coolant elbow. Heat the water pump housing to approx. 80°C and unscrew the coolant elbow. Clean the thread (remove LOCTITE resi- dues).
  • Page 303 BRP-Powertrain MAINTENANCE MANUAL INSPECTION Fig. 14 COOLING SYSTEM SINGLE PARTS - CHECK NOTICE WARNUNG Cracks in cooling system components are not permissible! If in doubt, check the affected parts for cracks using the dye penetrant method. NOTICE WARNUNG Preformed hoses must not be shortened, as this affects the position of the expansion tank.
  • Page 304 BRP-Powertrain MAINTENANCE MANUAL WATER PUMP HOUSING - INSPECTION Step Procedure Check the water pump housing for dam- age, deformation and leaks. Check the inner side for any signs of con- tact with the impeller. NOTE: If signs of contact are found, the water pump housing must be replaced.
  • Page 305 BRP-Powertrain MAINTENANCE MANUAL WEAR LIMITS Current measurement Tolerance Tolerance Measure- value limit limit Description ments 100 % 50 % Water pump Reference to WP01 8.55 mm 8.85 mm 8.85 mm current flat surface 0.3366 in. 0.3484 in. 0.3484 in. replaced Distance from impel- WP02 0.3 mm 0.5 mm...
  • Page 306 BRP-Powertrain MAINTENANCE MANUAL ASSEMBLY Fig. 18 IGNITION HOUSING - ASSEMBLY OIL SEAL - INSTALLATION Step Procedure Lubricate the outside of a new oil seal and press it into the ignition housing as far as the bottom with a suitable jig part no. 876510.
  • Page 307 BRP-Powertrain MAINTENANCE MANUAL WATER PUMP HOUSING - ASSEMBLY Step Procedure Install the ignition housing. Step Procedure See also section 24-20-00 Internal gener- Lubricate the new coolant elbow with ator. LOCTITE 243. Push on the stainless compensating shim Screw the coolant elbow at least 5 revolu- and apply LOCTITE 243 to the thread of tions into the water pump housing and po- the water pump shaft.
  • Page 308 BRP-Powertrain MAINTENANCE MANUAL COOLANT HOSE - INSTALLATION Step Procedure Install the spring type hose clip 35 on the NOTICE preformed hose radiator outlet. WARNUNG Push on the preformed hose radiator out- The push-on length of the expansion tank is 25 let and align it vertically.
  • Page 309 BRP-Powertrain MAINTENANCE MANUAL Fig. 24 Fig. 26 1. Spring type hose clip 35 2. Spring type hose clip 25 1. Preformed hose 1 2. Preformed hose 3 3. Preformed hose 3 4. Expansion tank 3. Expansion tank 5. Preformed hose radiator outlet Fig.
  • Page 310 BRP-Powertrain MAINTENANCE MANUAL Fig. 29 Step Procedure Install the spring type hose clip 25 on pre- formed hose 4. NOTE: Align the spring type hose clip 25 so that it does not come into contact with the other spring type hose clips. Push on preformed hose 4 and align it horizontally like preformed hoses 3 and 1.
  • Page 311 BRP-Powertrain MAINTENANCE MANUAL INSTALLATION Step Procedure IGNITION HOUSING - INSTALLATION Insert the o-ring in the water pump hous- ing and fasten the water inlet elbow in the See also section 24-20-00 Internal generator. marked position with 2 M6x20 Allen screws and lock washers. Tightening torque 10 Nm (88.48 in.
  • Page 312 BRP-Powertrain MAINTENANCE MANUAL NOTE: Check the push-on lengths, readjust the Fig. 33 preformed hoses if necessary. Step Procedure Install coolant elbows 1 to 4. See also section 72-30-00 Cylinder head. Mount 1 spring type hose clip 35 on the preformed hose radiator outlet and mount 1 spring type hose clip 25 each on pre- formed hoses 1, 2, 3, and 4.
  • Page 313 BRP-Powertrain MAINTENANCE MANUAL FINISHING WORK - Put the 2 cable ties on the knock sensor line. See also section 76-50-00 Wiring harness. - Install the double ignition coils and resistance spark plug connectors. See also section 74- 20-00 Ignition unit. - Install the air filter with the heat shield.
  • Page 314 BRP-Powertrain MAINTENANCE MANUAL NOTES 75-00-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 22 July 01/2012...
  • Page 315 - Fuse box (FUSE BOX) - Switches - Wiring Table of contents This section describes the maintenance of the ROTAX 912 i Series engine management unit assembly. The description is divided into sub- sections and explanations of system functions. Subject Section 1.
  • Page 316 BRP-Powertrain MAINTENANCE MANUAL Overview of engine management 76-00-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 2 July 01/2012...
  • Page 317 Introduction This section describes the system, the removal, installation and inspec- tion of the control unit (ECU) assembly of the ROTAX 912 i Series engine. In addition also the extraction of the ECU-Log files and the proce- dure of flashing ECU Software is described. The description is divided into sub-sections and explanations of system functions.
  • Page 318 BRP-Powertrain MAINTENANCE MANUAL NOTES 76-10-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 2 July 01/2012...
  • Page 319 BRP-Powertrain MAINTENANCE MANUAL Chapter: 76-10-00 CONTROL UNIT (ECU) SPECIAL TOOLS Description Part no. B.U.D.S SET LEVEL 1 864021 B.U.D.S SET LEVEL 2 864022 B.U.D.S SET LEVEL 3 864023 ECU Adapter 277012 Service Wiring Harness 864280 Y-Cable (Sub-D DE9 female on male/male junc- n.a.
  • Page 320 BRP-Powertrain MAINTENANCE MANUAL Control unit (ECU) 76-10-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 4 July 01/2012...
  • Page 321 BRP-Powertrain MAINTENANCE MANUAL SYSTEM DESCRIPTION Fig. 2 GENERAL NOTE The control unit is the central module in the engine management system. Sensors continuously measure pressure, rota- tion speed, temperature, load and knock signals and send these measurement values to the ECU.
  • Page 322 BRP-Powertrain MAINTENANCE MANUAL Fig. 3 06396 Control unit ECU 76-10-00 Effectivity: 912 i Series Edition 1/Rev. 1 Page 6 October 01/2013...
  • Page 323 BRP-Powertrain MAINTENANCE MANUAL MAINTENANCE Fig. 4 Beside maintenance and special checks, see the relevant Maintenance Manual Line for the respective 912 i Series engine type. REMOVAL Preparation Before the ECU is removed, the work and checks described below must be carried out to identify any malfunctions and rectify them as part of the repair work.
  • Page 324 BRP-Powertrain MAINTENANCE MANUAL INSPECTION INSTALLATION CONTROL UNIT - INSPECTION Preparation NOTICE NOTICE WARNUNG WARNUNG The plug connection of the ECU must be ope- The functional test of the ECU can only be car- ned and closed no more than 20 times! ried out with the corresponding software This must be shown on the device by a clearly (B.U.D.S.
  • Page 325 BRP-Powertrain MAINTENANCE MANUAL Fig. 6 Utility and Diagnostic Software (B.U.D.S. Air- craft). Generally the extraction of logs form an ECU can be performed in two differnt ways: - Situation 1: Extracting logs from a removed ECU. That means the ECU has been discon- nected from the wiring harness and removed from the aircraft.
  • Page 326 BRP-Powertrain MAINTENANCE MANUAL Connect Computer with ECU Step Procedure NOTICE WARNUNG Connect B.U.D.S. Aircraft Set with the USB-Port of your computer. Please note labeling of the ECU and the Service If the device is connected and installed Wiring Harness. the RED indicator light should light up. Step Procedure Connect the B.U.D.S.
  • Page 327 BRP-Powertrain MAINTENANCE MANUAL Extracting of log-files Fig. 10 Step Procedure Launch B.U.D.S. Aircraft by double click- ing the desktop icon. Alternatively B.U.D.S. Aircraft can also be started through the start menu entry (e.g. Start - Programs - BUDS - run BUDS). Fig.
  • Page 328 BRP-Powertrain MAINTENANCE MANUAL Fig. 13 Step Procedure Wait until connection state lights are “RED“ Connect power adapter with power sup- ply. The connection state (bottom-right corner of B.U.D.S.) for both LANES should turn “RED“ to “ORANGE“ and finally to “GREEN“. Fig.
  • Page 329 BRP-Powertrain MAINTENANCE MANUAL Fig. 14 09965 B.U.D.S. Aircraft settings for Log-extraction NOTICE WARNUNG Extraction process could take several minutes depending on the number of logs. Step Procedure Shut down the ECU (Unplug the power supply of the ECU). Disconnect the wiring attached to connect the ECU with the computer.
  • Page 330 BRP-Powertrain MAINTENANCE MANUAL SITUATION 2: Connect Computer with ECU EXTRACTING LOGS FROM AN IN- Step Procedure STALLED ECU (ON AIRCRAFT) Connect B.U.D.S. Aircraft Set with the USB-Port of your computer. NOTICE WARNUNG If the device is connected and installed the RED indicator light should light up. The battery must provide constant voltage thru Connect the B.U.D.S.
  • Page 331 BRP-Powertrain MAINTENANCE MANUAL Extracting of log-files Fig. 17 Step Procedure Launch B.U.D.S. Aircraft by double click- ing the desktop icon. Alternatively B.U.D.S. Aircraft can also be started through the start menu entry (e.g. Start - Programm - BUDS - run BUDS). Fig.
  • Page 332 BRP-Powertrain MAINTENANCE MANUAL Step Procedure Wait until connection state lamps are “RED“. Set “Backup-Battery“ and “Master“ Switch to “ON“. Set “LANE A“and “LANE B“ Switches to “ON“ (if connection Mode in “Preferences“ Menu set to “LANE A“ and “LANE B“). Fig.
  • Page 333 BRP-Powertrain MAINTENANCE MANUAL Fig. 20 Step Procedure In this window (“ECU Log Extraction“) choose respective LANE A and LANE B for Log-extraction (field:“ECU LANE Se- lection“). NOTE: If only one LANE has been con- nected or the user wants to ex- tract the logs from one LANE, the corresponding option must be selected here.
  • Page 334 BRP-Powertrain MAINTENANCE MANUAL Step Procedure Shut down the ECU. Switch “OFF“ “Backup Battery“ switch and “Master“ switch. “LANE A“ and “LANE B“ switches “OFF“. Disconnect the wiring specifically at- tached to connect the ECU with the com- puter. Disconnect USB to CAN Converter With the Windows Explorer navigate to the created Log-File.
  • Page 335 BRP-Powertrain MAINTENANCE MANUAL ECU SOFTWARE FLASHING SITUATION 1: UPDATING SOFTWARE OF A REMOVED ECU (ON BENCH) INTRODUCTION This section describes the process of flashing a NOTICE WARNUNG 912 iSeries ECU Software. Generally the ECU Software flashing process Removal must be carried out according to the can be done in two different ways: aircraft manufacturer's instructions.
  • Page 336 BRP-Powertrain MAINTENANCE MANUAL Set up wiring for the ECU Software flashing pro- NOTICE WARNUNG cess Step Procedure Please note labeling of the ECU and the Service Connect B.U.D.S. Aircraft Set with the Wiring Harness USB-Port of your computer. Step Procedure If the device is connected and installed the RED indicator light should light up.
  • Page 337 BRP-Powertrain MAINTENANCE MANUAL If the ECU at this time is supplied with Software flashing process with B.U.D.S. Aircraft NOTE: power, a restart is required. Step Procedure Step Procedure Open B.U.D.S. Aircraft Software. Wait until the Connection State Indicators Open the “Preferences“ Window and (Bottom-Right) turn to RED.
  • Page 338 BRP-Powertrain MAINTENANCE MANUAL The currently installed ECU Software NOTE: Fig. 28 version (“Software P/N“/section “ ECU Configuration Data“) and the set Engine Type (section “User Configu- rable Parameters“) can be seen in the “Connection“ Tab. The last three dig- its of the “Software P/N“ illustrate the currently installed ECU Software ver- sion.
  • Page 339 BRP-Powertrain MAINTENANCE MANUAL Check of the Software version Fig. 29 WARNING WARNUNG Do not disconnect or power down the ECU du- ring the software flashing process. If the Software flashing process was NOTE: interrupted (e.g. the ECU was discon- nected from the computer) it is neces- sary to restart the flashing process with the desired Software.
  • Page 340 BRP-Powertrain MAINTENANCE MANUAL SITUATION 2: Set up wiring for the ECU Software flashing pro- cess FLASHING SOFTWARE ON A INSTALLED ECU (ON AIRCRAFT) Step Procedure Connect B.U.D.S. Aircraft Set with the NOTICE WARNUNG USB-Port of your computer. If the device is connected and installed For a flawless Software flashing procedure en- the RED indicator light should light up.
  • Page 341 BRP-Powertrain MAINTENANCE MANUAL If the ECU at this time is supplied with The ECU software flashing process with B.U.D.S. NOTE: power, a restart is required. Aircraft Step Procedure Step Procedure Wait until the Connection State Indicators Open B.U.D.S. Aircraft Software. (Bottom-Right) turn to RED.
  • Page 342 BRP-Powertrain MAINTENANCE MANUAL The currently installed ECU Software NOTE: Step Procedure version (“Software P/N“/section “ Select “Load Package“. ECU Configuration Data“) and the set Engine Type (section “User Configu- Consequently a window will open to en- rable Parameters“) can be seen in the sure that the user is aware of flashing the “Connection“...
  • Page 343 BRP-Powertrain MAINTENANCE MANUAL FINISHING WORK Check of the Software version - Attach all the necessary fastenings (e.g. Step Procedure cable ties, holders, clamps etc.) of the wiring After the Software flashing process has harness. finished, the “Connection“-Tab will be shown. Check if the Software P/N equals - Transfer the actual data documented when the Softwareversion which was intended removing the old ECU to the newly installed...
  • Page 344 BRP-Powertrain MAINTENANCE MANUAL NOTES 76-10-00 Effectivity: 912 i Series Edition 1/Rev. 1 Page 28 October 01/2013...
  • Page 345 FUSE BOX (FUSE BOX) Introduction This section describes the system, the removal, installation and inspec- tion of the fuse box (FUSE BOX) assembly of the ROTAX 912 i Series engine. The description is divided into sub-sections and explanations of system functions.
  • Page 346 BRP-Powertrain MAINTENANCE MANUAL 1. Fuse box assy. 2. Rectifier regulator B 3. Rectifier regulator A 4. Sealing insert 5. Fuses 6. Heat transfer pad 76-10-00 Effectivity: 912 i Series Edition 1/Rev. 2 Page 30 July 01/2014...
  • Page 347 BRP-Powertrain MAINTENANCE MANUAL SYSTEM DESCRIPTION FUSE BOX - REMOVAL GENERAL NOTE Step Procedure Unplug the engine wiring harness and All the components of the voltage supply, e.g. grounding connectors from the fuse box. fuses, are included in the power supply unit. See also section 76-50-00 Wiring har- ness.
  • Page 348 BRP-Powertrain MAINTENANCE MANUAL Fig. 37 Fig. 36 1. Regulator A 2. Regulator B 1. Regulator A 2. Regulator B 3. Cover 4. Plastic washer M4 Connection bolt regulator A Connection bolt regulator B 5. M4 Allen screws Fig. 38 Step Procedure Disconnect the 2 RED/WHITE cable from connection bolt B+.
  • Page 349 BRP-Powertrain MAINTENANCE MANUAL REGULATOR A - REMOVAL Fig. 39 - The regulator A is removed analogously to regulator B. NOTICE WARNUNG The pin assignment of the ground cable is diffe- rent for rectifier regulator A and B. Wrench size of the gasket screw con- NOTE: nection: A/F 25.
  • Page 350 BRP-Powertrain MAINTENANCE MANUAL If the wire is broken or the connector INSTALLATION NOTE: is defective, the damage can be re- - The regulator is installed and removed in the paired. The cable must be long same way. The following should be noted. enough if the connector is cut off.
  • Page 351 BRP-Powertrain MAINTENANCE MANUAL Fig. 42 Fig. 43 1. Heat transfer pad 2. Regulator 1. Regulator B 2. Cup nut of the gasket screw connection 3. Thread of the gasket screw connection NOTICE WARNUNG The rectifier regulator must be mounted so that NOTICE WARNUNG it does not project beyond the regulator plate.
  • Page 352 BRP-Powertrain MAINTENANCE MANUAL Fig. 44 Step Procedure BLACK cable (2 pcs, labeled: B-) connect to connection bolt B-. Fasten the cable lug with locking nut M4 and washer on the connection bolt. The crimping of the lower cable lug must be directed towards the board of fuse box.
  • Page 353 BRP-Powertrain MAINTENANCE MANUAL Fig. 45 Fig. 46 1. Regulator A 2. Cup nut of the gasket 1. Cable BLACK 2. Washer 4.3 screw connection 3. Lock nut M4 4. Cup nut of the gasket 3. Thread of the gasket screw connection screw connection NOTICE WARNUNG...
  • Page 354 BRP-Powertrain MAINTENANCE MANUAL Fig. 47 NOTICE WARNUNG The cable lugs attached to the connecting ports A-, A and A+ must not touch each other (except those lugs which are attached to a connection bolt). Step Procedure BLACK cable (2 pcs, labeled: A-) connect to connection bolt A-.
  • Page 355 BRP-Powertrain MAINTENANCE MANUAL Fig. 48 Arrangement of the fuses 2 A Caution lamp B 5 A Injector 8 5 A Injector 7 5 A Start switch Not used 20 A ATO fuse 35 A ATO fuse 5 A Injector 6 5 A Injector 5 Fig.
  • Page 356 BRP-Powertrain MAINTENANCE MANUAL INSPECTION OF INSTALLATION OF THE regulator B. A conductive connection (continuity) must not be present. RECTIFIER REGULATOR Before installing the fuse box carry out a continu- NOTICE WARNUNG ity check using a multimeter between the regula- tor housing and rectifier regulator A and rectifier If a conductive connection (continuity) is pres- ent, the installation of the rectifier regulator has to be checked.
  • Page 357 BRP-Powertrain MAINTENANCE MANUAL INSPECTION OF THE FUSE BOX INSTAL- LATION Fig. 50. After the installation of the fuse box, use a multi- meter to carry out a continuity test between reg- ulator A and regulator B in the static condition. A continuity must not be present.
  • Page 358 BRP-Powertrain MAINTENANCE MANUAL NOTES 76-10-00 Effectivity: 912 i Series Edition 1/Rev. 2 Page 42 July 01/2014...
  • Page 359 WIRING HARNESS (MAIN STRAND) Introduction This section describes the system, the removal, installation and inspec- tion of the wiring harness assembly of the ROTAX 912 i Series engine. The description is divided into sub-sections and explanations of system functions. Subject Page 1.
  • Page 360 BRP-Powertrain MAINTENANCE MANUAL Subject Page (9) Fuel pump - connection Page 22 (10) Fuse box (FUSE BOX) - connection Page 22 (11) Ambient pressure sensor - connection Page 22 (12) Starter relay - connection Page 22 9. Finishing work Page 22 76-50-00 Effectivity: 912 i Series Edition 1/Rev.
  • Page 361 BRP-Powertrain MAINTENANCE MANUAL Chapter: 76-50-00 WIRING HARNESS (MAIN STRAND) SPECIAL TOOLS Description Part no. Maintenance Tool for EMS check ECU Adapter 277012 SERVICE PRODUCTS Description Part no. LOCTITE 243 897651 Effectivity: 912 i Series 76-50-00 Edition 1/Rev. 0 Page 3 July 01/2012...
  • Page 362 BRP-Powertrain MAINTENANCE MANUAL Wiring harness (main strand) 1. Wiring harness 76-50-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 4 July 01/2012...
  • Page 363 BRP-Powertrain MAINTENANCE MANUAL Detailed view 1. ECU LANE A1 Connector 2. ECU LANE A2 Connector 3. ECU LANE B Connector 4. FUSE BOX LANE B Con. 5. FUSE BOX LANE A Con. 6. AAPTS Sensor Connector 7. Starter relay 8. Starter relay 9.
  • Page 364 BRP-Powertrain MAINTENANCE MANUAL SYSTEM DESCRIPTION REMOVAL GENERAL NOTE Preparation Before the wiring harness is removed, the work The wiring harness consists essentially of two and checks described below must be carried out main parts, one for LANE A and one for LANE B. to identify any further malfunctions in the cylin- Both are each connected with connectors to the der head and rectify them as part of repair work.
  • Page 365 BRP-Powertrain MAINTENANCE MANUAL Fig. 1 FUSE BOX (FUSE BOX) - DISCONNECTI- - See also section 76-10-00 Fuse box. Step Procedure Loosen M5 hex. nut from the earthing ca- ble on controller A. Fig. 3 1. Starter relay 2. M6 hex. nut 3.
  • Page 366 BRP-Powertrain MAINTENANCE MANUAL Fig. 7 Step Procedure Mark the controller connector before de- taching. Push in the tab on the top of the connector and at the same time pull the connector out of the connection socket. Fig. 5 Round connectors have different groo- NOTE: ves and cannot be mixed up.
  • Page 367 BRP-Powertrain MAINTENANCE MANUAL CONTROL UNIT (ECU) - DISCONNECTI- Step Procedure Unplug the connectors (FUEL PUMP 1, FUEL PUMP 2) from the fuel pumps. See also section 76-10-00 Control unit. NOTE: First lift one side with a screwdri- Wiring harness designation: ver, fix the tab and then lift the - ECU LANE A1 lower tab with the screwdriver...
  • Page 368 BRP-Powertrain MAINTENANCE MANUAL Fig. 12 Fig. 13 1. M6x14 Allen screw 2. 6.4 washer 1. Lock 3. 12/M6 cable clamp Step Procedure EGT CONNECTOR AND IGNITION COIL - Pull out 4 ignition coil connectors from DISCONNECTION each side. See also section 74-20-00 Ignition unit. Use a suitable tool to pull out NOTE: the ignition coil plugs.
  • Page 369 BRP-Powertrain MAINTENANCE MANUAL Fig. 15 Fig. 17 1. EGT_1 2. EGT_2 1. Double ignition coils 2. Ignition coil connector (COIL_1, COIL_2, Step Procedure COIL_3, COIL_4) Loosen the M5x16 Allen screws with was- Step Procedure hers from double ignition coils. Carefully pull EGT_3 and EGT_4 (cylin- der 3/4) out of the locking plate.
  • Page 370 BRP-Powertrain MAINTENANCE MANUAL TEMPERATURE SENSOR - DISCONNEC- Fig. 20 TION Wiring harness designation: - CTS Step Procedure Disconnect the plug connection to the temperature sensor. Fig. 19 1. M5x12 Allen screw 2. 5.3 washer 3. Fuel rail cover Step Procedure Loosen 4 M5x12 Allen screws.
  • Page 371 BRP-Powertrain MAINTENANCE MANUAL Fig. 24 Fig. 22 1. Injector 2. Screwdriver 1. M5x12 Allen screw 2. 5.3 washer 3. Heat shield 4. M5x35 Allen screw THROTTLE POTENTIOMETER (TPS) - Step Procedure DISCONNECTION Disconnect the injectors. NOTE: The cables are labelled INJ_1 to NOTICE WARNUNG INJ_8.
  • Page 372 BRP-Powertrain MAINTENANCE MANUAL Fig. 25 Fig. 27 1. Pressure sensor 2. Cable ties 1. Throttle valve 2. Throttle potentiometer 3. Cable ties CRANKSHAFT POSITION SENSOR - DIS- CONNECTION TEMPERATURE SENSOR (OIL) AND Wiring harness designation: PRESSURE SENSOR (OIL) - DISCON. - CPS_1 for LANE A (yellow mark) Wiring harness designation: - CPS_2 for LANE B...
  • Page 373 BRP-Powertrain MAINTENANCE MANUAL KNOCK SENSOR - DISCONNECTION Fig. 30 Wiring harness designation: - KNOCK Fig. 28. Step Procedure Lift the latch and pull apart. AIRBOX PRESSURE SENSOR AND TEM- PERATURE SENSOR - DISCONNECTION Wiring harness designation: - MAPS_1 and MATS_1 for LANE A - MAPS_2 and MATS_2 for LANE B Step Procedure...
  • Page 374 BRP-Powertrain MAINTENANCE MANUAL It must be ensured that all plug-in Fig. 32 NOTE: connections are properly crimped with the cables. (There must be no bent, de- formed or loose pins in the plug connec- tions!) Electric test The electric test of the wiring harness takes place in the installed state.
  • Page 375 BRP-Powertrain MAINTENANCE MANUAL If necessary, clean the pins of the INSTALLATION NOTE: connector and coat them as follows: WIRING HARNESS - INSTALLATION AMP/ECU connector with a thin layer of Deoxit contact spray. Preparation All the other connectors with a dielectric silicone-based lubricant or an equivalent - Check all the wiring harness sections provi- lubricant.
  • Page 376 BRP-Powertrain MAINTENANCE MANUAL If the wire is broken or the connector is defective, the damage can be repaired. NOTE: The cable must be long enough if the connector is cut off. Repair with the tools described here must comply with the aircraft standard of the respective country.
  • Page 377 BRP-Powertrain MAINTENANCE MANUAL Pos. Part no. of connector set Corresponding tool 881306 Crimping pliers TYCO 539 635-1 Jaws TYCO 539 737-2 Disassembly tool DELPHI 12094429 881308 881302 Crimping pliers DELPHI 12155975 Disassembly tool DELPHI 12094429 881304 881294 Crimping pliers MOLEX 0638114400 Disassembly tool MOLEX 63813-1500 881312 Crimping pliers TYCO 58495-1‘...
  • Page 378 BRP-Powertrain MAINTENANCE MANUAL Fig. 37 Step Procedure Plug in the injectors according to the la- belling diagram. Fig. 36 1. Double ignition coil 2. Plug connection Step Procedure Tighten the M5x16 Allen screws and 5.3 washer. Tightening torque 5 Nm (44.25 in. lb.). Labelling diagram Fig.
  • Page 379 BRP-Powertrain MAINTENANCE MANUAL Fig. 39 NOTICE WARNUNG The Allen screws for the spring type hose clips go into the intake duct, they are therefore glued in with LOCTITE 243. Leaking Allen screws can cause an excessively lean mixture! STRAIN RELIEF - CONNECTION Step Procedure Attach strain reliefs to the wiring harness...
  • Page 380 BRP-Powertrain MAINTENANCE MANUAL CONTROL UNIT (ECU) - CONNECTION The sensors are connected and disconnected in the same way. See section 76-50-00 Removal. FUEL PUMP - CONNECTION The sensors are connected and disconnected in the same way. See section 76-50-00 Removal. FUSE BOX (FUSE BOX) - CONNECTION The sensors are connected and disconnected in the same way.
  • Page 381 MAINTENANCE MANUAL Chapter: 76-70-00 SENSORS AND ACTUATORS Introduction This section describes the maintenance of the sensor and actuator assembly of the ROTAX 912 i Series engine. The description is divided into sub-sections and explanations of system functions. Subject Page 1. Introduction Page 1 2.
  • Page 382 BRP-Powertrain MAINTENANCE MANUAL Subject Page O. Pressure/temperature sensor (AAPTS) - inspecti- Page 22 P. Injection valve - inspection Page 22 (1) Functional test Page 22 Q. Governor (electric) - inspection Page 22 R. Double ignition coil - inspection Page 23 S.
  • Page 383 BRP-Powertrain MAINTENANCE MANUAL Chapter: 76-70-00 SENSORS AND ACTUATORS SPECIAL TOOLS Description Part no. Multimeter n.a. 21x12.5 insert for MAPS and OPS 876075 19x12.5 insert for CTS and OTS 876130 SERVICE PRODUCTS Description Part no. LOCTITE 243 897651 LOCTITE ANTI SEIZE 297434 Effectivity: 912 i Series 76-70-00...
  • Page 384 BRP-Powertrain MAINTENANCE MANUAL Sensors 1. Crankshaft position sensor 2. Knock sensor 3. Ambient pressure sensor 4. Temperature sensor (CPS 1 + 2) (KNOCK) (AAPTS) (EGT) 5. Throttle potentiometer (TPS) 6. Temperature sensor 7. Pressure sensor 8. Temperature sensor (CTS and OTS) (MAPS 1 + 2) (MAPS 1 + 2) 9.
  • Page 385 BRP-Powertrain MAINTENANCE MANUAL Actuators 1. Ignition coils 2. Injection valves Effectivity: 912 i Series 76-70-00 Edition 1/Rev. 0 Page 5 July 01/2012...
  • Page 386 BRP-Powertrain MAINTENANCE MANUAL SYSTEM DESCRIPTION The temperature sensor measures the coolant temperature directly in the cylinder head of cylin- GENERAL NOTE der 4. In order to ensure that the engine is in the desi- 1 Temperature sensor – oil temperature red operating state and in full working order, a Wiring harness designation: OTS number of sensors are placed on it and used for...
  • Page 387 BRP-Powertrain MAINTENANCE MANUAL ACTUATORS AND INDICATORS MAINTENANCE Injection valve (INJ_1 to INJ_8): (Injector) For maintenance and special checks, see the relevant Maintenance Manual Line for the res- In the engine, eight injection valves (INJ) are pective 912 i Series engine type. used, two for each cylinder.
  • Page 388 BRP-Powertrain MAINTENANCE MANUAL Fig. 1 Step Procedure Loosen the pressure sensor with an SW 21 open-ended spanner (or a similar tool) LANE A Sensor LANE A and remove it. Close the threaded bore with the appro- priate protective covering. Fig. 3 LANE B Sensor LANE B 06341...
  • Page 389 BRP-Powertrain MAINTENANCE MANUAL Fig. 4 Fig. 5 1. Pressure/temperature sensor 2. Connection socket 1. Pressure sensor 2. Cable ties Step Procedure TEMPERATURE SENSOR (MATS_1+MAT- Loosen the pressure sensor with an SW S_2) - REMOVAL 19 open-ended spanner part no. 876130 Installation position: Airbox (or a similar tool) and remove it.
  • Page 390 BRP-Powertrain MAINTENANCE MANUAL Fig. 8 Step Procedure Unscrew the temperature sensor with an SW 19 open-ended spanner part no. 876130 (or similar tool) and remove it to- gether with the sealing ring. Close the threaded bore with the appro- priate protective covering. Fig.
  • Page 391 BRP-Powertrain MAINTENANCE MANUAL Fig. 10 Step Procedure Use an SW19 open-ended spanner part no. 876130 (or a similar tool) to re- move the temperature sensor from the crankcase. Close the bore with the appropriate pro- tective covering. TEMPERATURE SENSOR (CTS) - REMOVAL Installation position: Cylinder head (cylinder 4) Step...
  • Page 392 BRP-Powertrain MAINTENANCE MANUAL - Open the 1-ear clamp on the intake manifold Fig. 14 1/3. - Remove the intake manifold 1/3 assy. with the fuel rail and put it to one side. See also section 73-10-00 Fuel system. The assemblies and lines are only to be NOTE: removed if necessary and only as far as is necessary!
  • Page 393 BRP-Powertrain MAINTENANCE MANUAL CRANKSHAFT POSITION SENSOR ASSY. Fig. 17 (CPS_1, CPS_2) - REMOVAL Installation position: Ignition housing Step Procedure Unplug the respective connector of the wiring harness (main strand) from the cor- responding crankshaft position sensor as- sy. See also section 76-50-00 Wiring har- ness (main strand).
  • Page 394 BRP-Powertrain MAINTENANCE MANUAL Fig. 18 1. Throttle valve potentiometer 2. Throttle body assy. INJECTION VALVE (INJ) - REMOVAL To do this, see section 73-10-00 Fuel pump and distribution. GOVERNOR - REMOVAL See also section 61-20-00 Governor. DOUBLE IGNITION COIL - REMOVAL See also section 74-20-00 Distribution.
  • Page 395 BRP-Powertrain MAINTENANCE MANUAL INSPECTION GENERAL RESISTANCE MEASUREMENT SENSORS AND ACTUATORS Before checking the resistance, ensure that there is no voltage present at the component to INSPECTION/MEASUREMENT which the ohmmeter is connected. Always pull Preparation out the connectors beforehand. Switch off the Before starting to inspect the sensors NOTE: ignition.
  • Page 396 BRP-Powertrain MAINTENANCE MANUAL RESISTANCE MEASUREMENT (TEMPE- VOLTAGE MEASUREMENT RATURE SENSOR) General note General note NOTICE WARNUNG If resistance values are measured with an ohm- meter, all values are given at a temperature of Voltage supply: approx. 20 °C. A resistance value changes with The secondary side of the ignition unit is an temperature.
  • Page 397 BRP-Powertrain MAINTENANCE MANUAL CURRENT MEASUREMENT General note It is not often necessary to measure the ampe- rage on the engine. This requires an ammeter, which is usually integrated in a multimeter. NOTICE WARNUNG Amperage: Never measure the amperage in the cable to the starter with a normal ammeter! The measure- ment unit can be destroyed by the high currents which occur here.
  • Page 398 BRP-Powertrain MAINTENANCE MANUAL PRESSURE SENSOR (MAPS_1, MAPS_2) - INSPECTION Pressure sensor (MAPS_1, MAPS_2) Signal Voltage [in V] Remarks Supply voltage 5 V ± 0.5 0.5 ..4.5 V corresponds to 0 to 2 bar GROUND Measurement Current Pressure (bar/psi) [in V] 2 bar / 29 psi 4.5 V 06345...
  • Page 399 BRP-Powertrain MAINTENANCE MANUAL TEMPERATURE SENSOR (MATS_1/MATS_2) - INSPECTION Temperature sensor (MATS 1, MATS 2) Measurement Temperature [°C/°F] Resistance [Ω] -10 °C 9217 +/- 9 % 5808 +/- 7 % 20 °C 2500 +/- 5 % 80 °C 331 +/- 10 % 06354 06345 TEMPERATURE SENSOR (OTS) - INSPECTION...
  • Page 400 BRP-Powertrain MAINTENANCE MANUAL TEMPERATURE SENSOR (EGT 1, EGT 2, EGT 3, EGT 4) - INSPECTION Temperature sensor (EGT 1, EGT 2, EGT 3, EGT 4) Measurement Temperature [°C/°F] Resistance [Ω] -40 °C/-40 °F 169,7 0/32 °F 200,5 50 °C/122 °F 238,5 100 °C/212 °F 275,9...
  • Page 401 BRP-Powertrain MAINTENANCE MANUAL THROTTLE POTENTIOMETER (TPS) - - Corrosion or damage to the connector and contacts INSPECTION - Check that the sensor shaft moves freely Preparation - Check the parameters of the throttle valve Carry out a general visual inspection: setting with the Maintenance Tool (especially - Check the setting of the throttle valve actua- if the ECU or the throttle valve sensor have...
  • Page 402 BRP-Powertrain MAINTENANCE MANUAL PRESSURE/TEMPERATURE SENSOR (AAPTS) - INSPECTION Pressure/temperature sensor (AAPTS) Signal Value [in V] Remarks Supply voltage 5 V +/- 0,25 V Earth offset Signal temperature 45 kΩ - 89 Ω Pressure 0,25 V - 4,75 V Measurement Pressure [bar/psi] Voltage [in V] 0,35 bar/5.08 psi 1,41 V +/- 0,065 V...
  • Page 403 BRP-Powertrain MAINTENANCE MANUAL DOUBLE IGNITION COIL - INSPECTION - Corrosion or damage to the wiring, connector contacts or connections Preparation - Check the labelling of the connector Carry out a general visual inspection: Double ignition coil Measurement Position Resistance [Ω] Primary side 0,65 Ω...
  • Page 404 BRP-Powertrain MAINTENANCE MANUAL INSTALLATION Fig. 24 Preparation - Clean all parts carefully - Remove protective coverings PRESSURE SENSOR (OPS) - INSTALLA- TION Step Procedure Clean the thread of the pressure sensor. Lubricate the thread of the pressure sen- sor with LOCTITE 243 and use an SW 19 open-ended spanner part no.
  • Page 405 BRP-Powertrain MAINTENANCE MANUAL PRESSURE/TEMPERATURE SENSOR TEMPERATURE SENSOR (MATS) - INS- (AAPTS) - INSTALLATION TALLATION Step Procedure Step Procedure Follow the aircraft manufacturer's instruc- Clean the thread of the temperature sen- tions for assembly. sor. Plug the respective wiring harness con- Fasten the temperature sensor and seal- nector into the corresponding pressure or ing ring with an SW 19 open-ended span-...
  • Page 406 BRP-Powertrain MAINTENANCE MANUAL TEMPERATURE SENSOR (OTS) - INSTAL- Fig. 30 LATION Step Procedure Clean the thread of the temperature sen- sor. Lubricate the thread of the pressure sen- sor with LOCTITE 243 and use an SW 19 open-ended spanner part no. 876130 (or a similar tool) to tighten it.
  • Page 407 BRP-Powertrain MAINTENANCE MANUAL Fig. 33 Step Procedure Use an SW 17 torque wrench (or similar tool) to tighten the temperature sensors in the inlet pipes. Tightening torque 25 Nm (19 ft.lb.). Plug the respective wiring harness con- nector into the corresponding pressure or temperature sensor.
  • Page 408 BRP-Powertrain MAINTENANCE MANUAL Fig. 35 Fig. 36 1. Cable ties 1. Crankshaft position 2. Crankshaft position sensor CPS_1 sensor CPS_2 FINISHING WORK ON THE KNOCK SEN- 3. M6x20 allen screw 4. Washer 5. Cable clamp 6. O-ring Follow the same procedure as removal when doing this work.
  • Page 409 BRP-Powertrain MAINTENANCE MANUAL THROTTLE POTENTIOMETER (TPS) - IN- FINISHING WORK STALLATION - Complete the engine Step Procedure - Fill with operating fluids (coolant, oil or fuel). See also section 12-20-00 Planned mainte- Install the throttle body assy. To do this, nance.
  • Page 410 BRP-Powertrain MAINTENANCE MANUAL NOTES 76-70-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 30 July 01/2012...
  • Page 411 MAINTENANCE MANUAL Chapter: 78-00-00 EXHAUST SYSTEM Introduction This section describes the maintenance of the exhaust system assembly of the ROTAX 912 i Series engine. The description is divided into sub- sections and explanations of system functions. Subject Page 1. Introduction Chapter 78-00-00 A.
  • Page 412 BRP-Powertrain MAINTENANCE MANUAL Exhaust system 78-00-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 2 July 01/2012...
  • Page 413 BRP-Powertrain MAINTENANCE MANUAL SYSTEM DESCRIPTION CONNECTIONS FOR DISPLAY SYSTEMS The exhaust system of the ROTAX 912 i Series NOTICE WARNUNG engine is optional. If it was not ordered when the engine was purchased, only the 4 exhaust sock- Follow the instructions in the Installation Manual ets on the cylinder head are supplied.
  • Page 414 BRP-Powertrain MAINTENANCE MANUAL NOTES 78-00-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 4 July 01/2012...
  • Page 415 EXHAUST (OPTIONAL) Introduction This section describes the maintenance of the optionally available exhaust of the ROTAX 912 i Series engine. The description is divided into sub-sections and explanations of system functions. NOTE: For non-ORIGINAL ROTAX exhaust systems, use the main- tenance manual of the aircraft manufacturer.
  • Page 416 BRP-Powertrain MAINTENANCE MANUAL 1. Muffler assy. 2. Tension spring 3. Exhaust pipe 5. Exhaust flange 6. Outflow pipe / exhaust elbow 78-10-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 2 July 01/2012...
  • Page 417 BRP-Powertrain MAINTENANCE MANUAL Chapter: 78-10-00 EXHAUST SERVICE PRODUCTS Description Part no. LOCTITE 648 899788 LOCTITE ANTI SEIZE 15378 297434 Effectivity: 912 i Series 78-10-00 Edition 1/Rev. 0 Page 3 July 01/2012...
  • Page 418 BRP-Powertrain MAINTENANCE MANUAL Exhaust 78-10-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 4 July 01/2012...
  • Page 419 BRP-Powertrain MAINTENANCE MANUAL SYSTEM DESCRIPTION Fig. 1 The exhaust collects the gases produced in the combustion chamber, leads them via the exhaust manifold to the muffler, which is used to reduce noise. The exhaust gas passes via the outflow pipe through a tail pipe into the open. MAINTENANCE As well as the maintenance and special checks, see the relevant Maintenance Manual Line for...
  • Page 420 BRP-Powertrain MAINTENANCE MANUAL INSPECTION Fig. 4 EXHAUST ASSY. - INSPECTION NOTICE WARNUNG Follow the aircraft manufacturer's instructions for inspection. Step Procedure Check the exhaust for cracks, dents and leaks. EXHAUST PIPE AND CYLINDER HEAD - INSPECTION 1. Conical seal 2. Cylinder head NOTICE WARNUNG A deformed exhaust flange must be replaced!
  • Page 421 BRP-Powertrain MAINTENANCE MANUAL INSTALLATION EXHAUST PIPE ON CYLINDER HEAD - INSTALLATION Step Procedure Check that the studs are firmly in place. Secure them with LOCTITE 648 if neces- sary and tighten them. Tightening torque 6 Nm (53.09 in. lb.) Fasten the exhaust flange to the cylinder head with 2 new M8 hex.
  • Page 422 BRP-Powertrain MAINTENANCE MANUAL NOTES 78-10-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 8 July 01/2012...
  • Page 423 MAINTENANCE MANUAL Chapter: 79-00-00 LUBRICATION SYSTEM Introduction This section describes the maintenance of the lubrication system assem- bly of the ROTAX 912 i Series engine. The description is divided into sub- sections and explanations of system functions. Subject Page 1. Introduction Page 1 2.
  • Page 424 BRP-Powertrain MAINTENANCE MANUAL Subject Page 19. Removal Page 21 A. Preparation Page 21 B. Removal of the oil cooler Page 21 20. Inspection Page 22 A. Oil cooler - inspection Page 22 21. Installation Page 22 A. Oil cooler - installation Page 22 22.
  • Page 425 BRP-Powertrain MAINTENANCE MANUAL Effectivity: 912 i Series 79-00-00 Edition 1/Rev. 0 Page 3 July 01/2012...
  • Page 426 BRP-Powertrain MAINTENANCE MANUAL NOTES 79-00-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 4 July 01/2012...
  • Page 427 BRP-Powertrain MAINTENANCE MANUAL Chapter: 79-00-00 LUBRICATION SYSTEM SPECIAL TOOLS Description Part no. Oil filter wrench 877620 Dial gauge n.a. Straight-edge n.a. Aligning plate n.a. SERVICE PRODUCTS Description Part no. KLUEBER ISOFLEX TOBAS NB 5051 898351 LOCTITE 5910 899791 LOCTITE 243 897651 Insulating tape n.a.
  • Page 428 BRP-Powertrain MAINTENANCE MANUAL Lubrication system 79-00-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 6 July 01/2012...
  • Page 429 BRP-Powertrain MAINTENANCE MANUAL SYSTEM DESCRIPTION CONNECTIONS FOR DISPLAY SYSTEMS The engine is lubricated with dry sump forced NOTICE WARNUNG lubrication and is equipped with a trochoid oil pump with an integrated pressure regulator. The Follow the instructions in the Installation Manual oil pump sucks the engine oil from the oil tank regarding connections for instrumentation.
  • Page 430 BRP-Powertrain MAINTENANCE MANUAL Fig. 1 Fig. 3 Step Procedure Step Procedure Loosen 4 Allen screws with lock washers. Disconnect the regulator pressure oil line Remove the whole oil pump unit and o- (if present). rings. Remove the safety wire of the plug screw Fig.
  • Page 431 BRP-Powertrain MAINTENANCE MANUAL DISASSEMBLY NOTICE WARNUNG OIL PUMP - DISASSEMBLY The rotary piston and rotor are marked. Fig. 4 Fig. Step Procedure Fig. 6 Remove the plug screw, compression spring and regulator piston. Fig. 4 1. Rotor (inner rotor) 2. Rotary piston (outer rotor) 3.
  • Page 432 BRP-Powertrain MAINTENANCE MANUAL Fig. 8 1. Oil seal 2. Oil pump shaft Step Procedure Carefully lever the oil seal out of the oil pump housing with a screwdriver. Fig. 9 1. Screwdriver 2. Oil seal Effectivity: 912 i Series 79-00-00 Edition 1/Rev.
  • Page 433 BRP-Powertrain MAINTENANCE MANUAL INSPECTION Fig. 11 OIL PUMP SINGLE PARTS - CHECK Preparatory work - Clean all parts carefully. See also section 05- 00-00 Procedures OIL PUMP HOUSING - INSPECTION Step Procedure Visually inspect all the components of the oil pump. All the o-rings must be replaced.
  • Page 434 BRP-Powertrain MAINTENANCE MANUAL OIL PUMP SHAFT - INSPECTION Step Procedure Check the oil pump shaft at the bearing points. Check the feather key groove and feather key for wear. Fig. 13 1. Oil pump shaft 2. Feather key Effectivity: 912 i Series 79-00-00 Edition 1/Rev.
  • Page 435 BRP-Powertrain MAINTENANCE MANUAL WEAR LIMITS Fig. 14 Oil pump Current measure- Tolerance Tolerance ment value limit limit Description Measurements 100 % 50 % Main pump spacing OP01 0.02 mm 0.07 mm 0.20 mm 0.14 mm current (pump cover/rotor) 0.00079 in. 0.0027 in.
  • Page 436 BRP-Powertrain MAINTENANCE MANUAL ASSEMBLY Fig. 16 OIL PUMP - ASSEMBLY Whenever the ignition housing is instal- NOTE: led or assembled, new acid-free greased o-rings and other sealing elements must always be used correctly! Step Procedure Apply Klueber grease to the plug screw. Screw the plug screw with the pressure spring and the regulator piston finger-tight into the oil pump housing.
  • Page 437 BRP-Powertrain MAINTENANCE MANUAL OIL PUMP HOUSING O-RINGS Step Procedure Insert the feather key in the oil pump NOTICE WARNUNG shaft. Fig. 18 All the o-rings must be replaced! Step Procedure Insert new o-rings in the oil pump housing. Fig. 20 1.
  • Page 438 BRP-Powertrain MAINTENANCE MANUAL Fig. 21 NOTICE WARNUNG Make sure the oil pump cover is in the correct position when putting it on. Step Procedure Place the oil pump cover on the oil pump housing. Fig. 21 1. Oil pump cover Effectivity: 912 i Series 79-00-00 Edition 1/Rev.
  • Page 439 BRP-Powertrain MAINTENANCE MANUAL INSTALLATION Fig. 23 OIL PUMP - INSTALLATION Preparation - Check the fit of the o-rings on the oil pump housing NOTICE WARNUNG Ensure that the oil pump shaft is in the correct installation position. Fig. 22 1. Crankcase Step Procedure Install the oil pump housing with M6x50...
  • Page 440 BRP-Powertrain MAINTENANCE MANUAL OIL FILTER INSTALLATION Step Procedure Install the oil filter. See relevant Main- tenance Manual Line for the 912 i Series. NOTE: Oil the gasket of the oil seal. Install the oil lines. FINISHING WORK - Fill with fresh oil. See relevant Maintenance Manual Line for the 912 i Series.
  • Page 441 BRP-Powertrain MAINTENANCE MANUAL REMOVAL Fig. 25 REMOVAL OF THE OIL TANK WARNING WARNUNG Danger of severe burns and scalds! Always allow the engine to cool down to ambient tempe- rature before starting any work. WARNING WARNUNG Danger of electric shock! Switch off the ignition and pull out the ignition key! Disconnect the ne- gative terminal of the battery.
  • Page 442 BRP-Powertrain MAINTENANCE MANUAL DISASSEMBLY Fig. 27 OIL TANK - DISASSEMBLY Fig. 26 Fig. 27 Step Procedure Open profile clamp 163. Remove the oil tank cover assy. and O-ring. Fig. 26 1. Oil tank 2. Baffle insert 3. Partition INSPECTION OIL TANK SINGLE PARTS - CHECK Preparation - Clean all parts carefully.
  • Page 443 BRP-Powertrain MAINTENANCE MANUAL Fig. 28 REMOVAL REMOVAL OF THE OIL COOLER NOTICE WARNUNG The oil cooler is not included in the delivery of the engine. Maintenance must be carried out in accordance with the aircraft manufacturer's in- structions. WARNING WARNUNG Danger of severe burns and scalds! Always allow the engine to cool down to ambient tempe- rature before starting any work.
  • Page 444 BRP-Powertrain MAINTENANCE MANUAL INSPECTION FINISHING WORK OIL COOLER - INSPECTION - Fill with fresh oil. See relevant Maintenance Manual Line for the 912 i Series. NOTICE WARNUNG - Bleed the oil system. The oil cooler is not included in the delivery of See relevant Maintenance Manual Line for the engine.
  • Page 445 BRP-Powertrain MAINTENANCE MANUAL REMOVAL Fig. 29 REMOVAL OF THE OIL LINE NOTICE WARNUNG The oil lines are not included in the delivery of the engine and must be maintained according to the aircraft manufacturer's instructions. Step Procedure Remove the oil lines and clamps accor- ding to the instructions in the aircraft ma- nufacturer's manual.
  • Page 446 BRP-Powertrain MAINTENANCE MANUAL INSTALLATION TEMPERATURE AND PRESSURE MEA- SUREMENT SYSTEM OIL LINE - INSTALLATION TEMPERATURE SENSOR (OIL) NOTICE WARNUNG General note The temperature sensor for measuring the oil Ensure that the lines are installed without tensi- temperature is screwed into the crankcase. The on and are not scuffed.
  • Page 447 BRP-Powertrain MAINTENANCE MANUAL REMOVAL NOTICE WARNUNG TEMPERATURE SENSOR (OIL) - REMOVAL The temperature must be no more or less than the max. operating temperature. Step Procedure To do this, see section 76-70-00 Sensors and actuators. REMOVAL Clean the thread of the oil temperature PRESSURE SENSOR (OIL) - sensor.
  • Page 448 BRP-Powertrain MAINTENANCE MANUAL COMPONENT REPAIR THREAD MAGNETIC DRAIN PLUG See relevant Maintenance Manual Line for the 912 i Series engine type. It is possible to repair the thread of the NOTE: magnetic plug in the crankcase with a HeliCoil. DRAIN PLUG See relevant Maintenance Manual Line for the 912 i Series engine type.
  • Page 449 MAINTENANCE MANUAL Chapter: 80-00-00 ELECTRIC STARTER Introduction This section describes the maintenance of the electric starter assembly of the ROTAX 912 i Series engine. The description is divided into sub-sec- tions and explanations of system functions. Subject Page 1. Introduction Page 1 2.
  • Page 450 BRP-Powertrain MAINTENANCE MANUAL 80-00-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 2 July 01/2012...
  • Page 451 BRP-Powertrain MAINTENANCE MANUAL Chapter: 80-00-00 ELECTRIC STARTER SERVICE PRODUCTS Description Part no. KLUEBER ISOFLEX TOPAS Nb5051 898351 Effectivity: 912 i Series 80-00-00 Edition 1/Rev. 0 Page 3 July 01/2012...
  • Page 452 BRP-Powertrain MAINTENANCE MANUAL Electric starter 80-00-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 4 July 01/2012...
  • Page 453 BRP-Powertrain MAINTENANCE MANUAL SYSTEM DESCRIPTION Fig. 1 The electric starter is a DC motor with a perma- nent magnet and carbon brushes. The gear- tooth system of the armature shaft is perma- nently engaged in the idler gear. During the star- ting process the sprag clutch forms a connection to the crankshaft via the idler gear and free wheel gear.
  • Page 454 BRP-Powertrain MAINTENANCE MANUAL NOTICE WARNUNG Do not tap the electric starter with a hammer, the adhering magnets can come off. If the o-ring (fig. 3) sticks, first press the NOTE: electric star ter gently down with a screwdriver and then pull off the starter by hand.
  • Page 455 BRP-Powertrain MAINTENANCE MANUAL INSTALLATION Fig. 5 ELECTRIC STARTER - INSTALLATION Preparation - Check that the o-rings are securely fitted on the bearing flange. - Lightly grease the o-ring on the bearing flange and the centring bore in the ignition housing with KLUEBER ISOFLEX TOPAS Nb5051.
  • Page 456 BRP-Powertrain MAINTENANCE MANUAL NOTES 80-00-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 8 July 01/2012...
  • Page 458 AIRCRAFT ENGINES __________________________________________________________ Engine serial no. __________________________________________________________ Type of aircraft __________________________________________________________ Aircraft registration no. ROTAX® authorized distributor ® and TM are trademarks of BRP-Rotax GmbH & Co KG. © 2018 BRP-Rotax GmbH & Co KG. All rights reserved...

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