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

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AIRCRAFT ENGINES
ref. no.: MMH-912 i | part no.: 898751

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Summary of Contents for Rotax 912 i Series

  • Page 1 AIRCRAFT ENGINES ref. no.: MMH-912 i | part no.: 898751...
  • Page 2 BRP-Powertrain GmbH&Co KG, be disclosed in whole or in part to third parties. This legend shall be included on any reproduction of these data, in whole or in part. Copyright 201 © - all rights reserved. ROTAX is a trade mark of BRP-Powertrain GmbH&Co KG. In the following document the ®...
  • Page 3 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 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 37-00-00 2012 07 01 2012 07 01 Effectivity: 912 i Series Edition 1/Rev. 1 Page 1 October 01/2013...
  • Page 6 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 Effectivity: 912 i Series Edition 1/Rev. 0 Page 2 July 01/2012...
  • Page 7 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 Effectivity: 912 i Series Edition 1/Rev. 0 Page 3 July 01/2012...
  • Page 8 2012 07 01 2012 07 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 Effectivity: 912 i Series Edition 1/Rev. 1 Page 4 October 01/2013...
  • Page 9 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 78-00-00 2012 07 01 Rear page 2012 07 01 2012 07 01 2012 07 01 Effectivity: 912 i Series Edition 1/Rev. 1 Page 5 October 01/2013...
  • Page 10 BRP-Powertrain MAINTENANCE MANUAL NOTES Effectivity: 912 i Series Edition 1/Rev. 0 Page 6 July 01/2012...
  • Page 11 07 01 2012 DOA* 79-00-00 07 01 2012 DOA* 80-00-00 07 01 2012 DOA* INTRO 10 01 2013 DOA* 1 - 4 10 01 2013 DOA* 10 01 2013 DOA* Effectivity: 912 i Series Edition 1/Rev. 1 Page 1 October 01/2013...
  • Page 12 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 10 01 2013 DOA* Effectivity: 912 i Series Edition 1/Rev. 1 Page 2 October 01/2013...
  • Page 13 New illustrations, new tooling (see revision bars). 13,14-20 10 01 2013 Illustration (special tools) added. 76-10-00 1-28 10 01 2013 Illustration (special tools) added, 29-36 10 01 2013 Chapter ECU revision, New Text, New Illustration Effectivity: 912 i Series Edition 1/Rev. 1 Page 3 October 01/2013...
  • Page 14 BRP-Powertrain MAINTENANCE MANUAL NOTES Effectivity: 912 i Series Edition 1/Rev. 0 Page 4 July 01/2012...

  • Page 15: Table Of Contents

    BRP-Powertrain MAINTENANCE MANUAL Chapter: 00-00-00 GENERAL NOTE This manual describes maintenance of all ROTAX 912 i Series engines. Introduction ROTAX 912 i Series includes 912 iSc and 912 iS. 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

    For additional information on engines, maintenance or parts, you can also con- tact your nearest authorized ROTAX-aircraft engine distributor. For ROTAX Authorized Distributors for Aircraft Engines see latest Operators ROTAX Distributors Manual or on the Internet at the official Website www.FLYROTAX.com.
  • 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

    Counter-clockwise DCDI Dual Capacitor Discharge Ignition direct current Design Organisation Approval Department of Transport EASA European Aviation Safety Agency Engine Control Unit Exhaust Gas Temperature Engine Management System Effectivity: 912 i Series 00-00-00 Edition 1/Rev. 0 Page 5 July 01/2012...
  • Page 20 Production Organisation Approval power take off side Rev. Revision Research Octane Number ROTAX is a trade mark of BRP-Powertrain GmbH & Co KG Revolutions per minute Society of Automotive Engineers 00-00-00 Effectivity: 912 i Series Edition 1/Rev. 1 Page 6 October 01/2013...
  • Page 21 Table of amendments Type certificate Table of Contents Time Since New TSNP Time Since New Part Time Since Overhaul Volt Visual Flight Rules shows the serial component number Effectivity: 912 i Series 00-00-00 Edition 1/Rev. 0 Page 7 July 01/2012...

  • Page 22: Conversion Table

    21 13 8.4 5.3 3.3 2.1 1.3 0.8 0.52 1 bar = 100 000 Pa/1000 hPa/ 100 kPa 1 bar = 14.5037 lbf/in (psi) 1 in Hg = 33.8638 hPa 00-00-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 8 July 01/2012...

  • Page 23: Safety Notice

    ENVIRONMENT NOTE Environment note gives you tips and behaviors to environmental protec- tion. A revision bar outside of the page margin indicates a change to text or graphic. Effectivity: 912 i Series 00-00-00 Edition 1/Rev. 0 Page 9 July 01/2012...

  • Page 24: Safety Information

    MAINTENANCE MANUAL 3.1) Safety information This information relates to the preparation and use of ROTAX aircraft engines General note and has been utilized safely and effectively by BRP-Powertrain. However, BRP- Powertrain disclaims liability for all damage and/or injuries resulting from the improper use of the contents.
  • 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

    WARNUNG Spare parts must meet with the requirements defined by the engine manufactu- rer. This is only warranted by use of GENUINE ROTAX spare parts and/or accessories (see IPC) or suitable equivalent in the manufacturer’s opinion otherwise, any limited warranty by BRP-Powertrain is null and void (see War- ranty Conditions).

  • Page 27: Maintenance Concept

    "Line Maintenance". This Manual can only be used in combination with Maintenance Ma- NOTE: nual I (Line Maintenance), as it builds up on it. Effectivity: 912 i Series 00-00-00 Edition 1/Rev. 0 Page 13...

  • Page 28: Technical Documentation

    The status of the Manuals can be determined with the aid of the table of amend- Status ments. The first column indicates the revision state. This figure should be compa- red with the revision provided on ROTAX Aircraft Engines Website: www.FLYROTAX.com. Amendments and current versions can be downloaded free of charge.
  • Page 29 The Illustrations in this Manual are stored in a graphic data base sys- NOTE: tem and are provided with a consecutive irrelevant number. This number (e.g. 00277) is of no significance for the content. Effectivity: 912 i Series 00-00-00 Edition 1/Rev. 0 Page 15...

  • Page 30: Use For Intended Purpose

    Never run an engine without propeller. Flying components can cause serious injuries. The engine ROTAX 912 iSc is intended for use in certified aircraft. In case of doubt the regulations of the national authorities or the respective sportive federa- tions have to be observed.

  • Page 31: Inspection Of Parts And Report Of Findings

    NOTICE WARNUNG Where measurement values are taken in hundredths of a millimeter or more precisely, the temperature of the part must be 20 to 25 °C (68 to 77 °F). Effectivity: 912 i Series 00-00-00 Edition 1/Rev. 0 Page 17...
  • Page 32 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 valve train water pump 00-00-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 18 July 01/2012...

  • Page 33: Classification Of Parts For Maintenance/Repair

    (100 %) of the part in question). - The classification is carried out as per following table: TSN [h] max. permissible wear Time Since New for repair [%] from TBO 2000 h - 912 i Series 1000 1001 1100 1101 1200 1201 1300...
  • 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.
  • Page 35 28,10 mm (1.1062 in.) Actual dimension 28,07 mm (1.1051 in.) Actual wear 57,1 % This part must be replaced because it is excessively worn for only 300 hours of operation. Effectivity: 912 i Series 00-00-00 Edition 1/Rev. 0 Page 21 July 01/2012...
  • 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

    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 Engine oil for easier assembly of components or for first lubrication before first engine start 899791 LOCTITE 5910 50 ml flange sealant provides flexibility and adhesion 00-00-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 24 July 01/2012...
  • Page 39 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 LOCTITE, clean surfaces with nitrothinner or degreasing agent (CASTROL ZA 30 or OMV - SOFT SOL). When using solvents, observe the safety regulations for per- sons and the environment. 00-00-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 26 July 01/2012...
  • Page 41 To achieve the direction changes of the magnetic field vector necessary for indication of cracks in any direction, the alternating currents serving as the cur- rent supply for the different methods of magnetizing are dephased by 120° to each other. Effectivity: 912 i Series 00-00-00 Edition 1/Rev. 0 Page 27...
  • Page 42 Fig. 5 shows one possible tensioning device for the disassembly of the pro- peller gearbox. The dimensions given are only intended for easier orientation and are not binding. Fig. 5 07525 00-00-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 28 July 01/2012...
  • Page 43 25x52x15, oil seal 30x52x7 and oil inlet cover 242091 hex. nut M10 for roller bearing 25x52x15, oil seal 30x52x7 and oil feed line cover Effectivity: 912 i Series 00-00-00 Edition 1/Rev. 0 Page 29 July 01/2012...
  • Page 44 877460 reducing socket wrench 3/4“-1/2“ 877802 installation tool assy. for piston pin circlip installation 33-34 877091 piston pin extractor assy. for assembly and disassembly of the piston pin 00-00-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 30 July 01/2012...
  • Page 45 876180 socket driver T30 ball head for screws of intake manifold 876240 socket driver hex. 8 ball head for cyl. screws Effectivity: 912 i Series 00-00-00 Edition 1/Rev. 1 Page 31 October 01/2013...
  • Page 46 M18x1 for cleaning of fine thread when replacing the coolant fitting 877670 exhaust pipe trimmer to slice the oil filter 877520 measuring tool - crankshaft torsion 00-00-00 Effectivity: 912 i Series Edition 1/Rev. 1 Page 32 October 01/2013...
  • 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 Seite 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 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. Effectivity: 912 i Series 24-20-00 Edition 1/Rev. 1 Page 3 October 01/2013...
  • 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 - Engine cleaning. See relevant Maintenance SAFETY INFORMATION Manual Line for the 912 i Series engine type. - Carry out an engine test run. See relevant WARNUNG WARNING Maintenance Manual Line for the 912 i Series engine type.
  • Page 56 - Drain coolant. See relevant Maintenance Manual Line for the 912 i Series engine type. - Remove adjacent assemblies (electric starter, water pump). - Remove coolant hoses from cylinder head.
  • Page 57 Remove Oil seal with a screwdriver. NOTICE WARNUNG Take care not to damage the Oil seal contact surface in the ignition housing. 1. Ignition housing assy. 2. Puller assy. part.no. 876010 24-20-00 Effectivity: 912 i Series Edition 1/Rev. 1 Page 7 October 01/2013...
  • Page 58 1. Dowel pin 2. Plug screws FLY WHEEL ASSY. REMOVAL Preparation - Fix the crankshaft into place. See relevant Maintenance Manual Line for the 912 i Series engine type. Step Procedure Loosen 6 M6x12 Allen screws. Remove the fly wheel.
  • Page 59 Unscrew lock nut and remove the washer, disk springs and distance sleeve. Remove the adjustment screw and lead- through seal. Note the location of the cable clamps for NOTE: reassembly! 24-20-00 Effectivity: 912 i Series Edition 1/Rev. 1 Page 9 October 01/2013...
  • Page 60 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 cable out. Effectivity: 912 i Series 24-20-00 Edition 1/Rev. 1 Page 10 October 01/2013...
  • Page 61 Step Procedure Check the bearing bushing for damage and wear. Check that the oil bore is clear. 24-20-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 11 July 01/2012...
  • Page 62 1.5 mm (0.06 in.) by omitting the washer. Fig. 22 1. Fly wheel assy. 2. Stator assy. 3. Controller connectors A, B 4. Lead-through seal 1. Oil seal 2. Washer Effectivity: 912 i Series 24-20-00 Edition 1/Rev. 0 Page 12 July 01/2012...
  • Page 63 0.0020 in. 0.0047 in. 0.0033 in. replaced Crankshaft end CS05 27.970 mm 28.000 mm 27.930 mm 27.950 mm current 1.1012 in 1.103 in 1.0996 in 1.1004 in replaced 24-20-00 Effectivity: 912 i Series Edition 1/Rev. 1 Page 13 October 01/2013...
  • Page 64 1. Oil seal positioned 2. Insertion jig STATOR ASSY. - INSTALLATION Step Procedure Thread in the cable and then secure M4x8 adjustment screw with LOCTITE 243 and tighten them. Effectivity: 912 i Series 24-20-00 Edition 1/Rev. 1 Page 14 October 01/2013...
  • Page 65 Make the cable sleeves latch. When assembling the controller connec- NOTE: tor, note the marks made. 1. Separation between the two generator coils 2. M5x30 Allen screw 3. Washer A 5.5 24-20-00 Effectivity: 912 i Series Edition 1/Rev. 1 Page 15 October 01/2013...
  • Page 66 2. Cable clamp 8/M6 mentioned here must conform to the air- craft standards of the respective country. Part no. of connector set Corresponding tool 866420 DEUTSCH HDT- 48 - 00 866422 Effectivity: 912 i Series 24-20-00 Edition 1/Rev. 1 Page 16 October 01/2013...
  • Page 67 2. O-ring 5x2 Step Procedure Install puller assy. part no. 876010 on ig- nition housing. Lubricate the sealing sur- face of the ignition housing with LOCTITE 5910. 1. Dowel pins 24-20-00 Effectivity: 912 i Series Edition 1/Rev. 1 Page 17 October 01/2013...
  • Page 68 NOTICE WARNUNG Fingers can be crushed. Do not use a longer screw! The screw would press on the cylinder shroud and cause damage to piston and cylinder. Effectivity: 912 i Series 24-20-00 Edition 1/Rev. 1 Page 18 October 01/2013...
  • Page 69 76-70-00 Sensors and actuators. Fig. 41 - Install airbox on ignition housing. See also section 73-10-00 Fuel system. - Release crankshaft. See relevant Main- tenance Manual Line for the 912 i Series engine type. 1. M6x65 Allen screw 2. Water pump wheel Step Procedure Fasten M5x45 hex.
  • 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 Seite 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 There is a risk of short circuits and cable fires engine test run. See relevant Maintenance during work on the electric system. Manual Line for the 912 i Series engine type. All installation work on the electric system - Output voltage check. See "Documentation of should be carried out with the engine switched aircraft manufacturer"...
  • 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 3. External alternator Remove the tension bar underneath the Fig. 4 external generator. Step Procedure Loosen 2 M8x20 Allen screws along with lock washers and remove the alternator bracket. 24-30-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 5 July 01/2012...
  • Page 76 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. Lock washers 3. M6x50 Allen screws Effectivity: 912 i Series 24-30-00 Edition 1/Rev. 0 Page 6 July 01/2012...
  • Page 77 2. M8x20 Allen screw 3. M6x50 Allen screws Step Procedure Attach the alternator bracket finger-tight to the gearbox housing using the two M8x20 Allen screws and VHZ8 lock wash- ers. 24-30-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 7 July 01/2012...
  • Page 78 Step Procedure Tighten the pre-mounted M6 and M8 Al- len screws. Tightening torque 10 Nm (88.48 in. lb.) Place the v-belt in the v-belt pulley of the alternator. Effectivity: 912 i Series 24-30-00 Edition 1/Rev. 0 Page 8 July 01/2012...
  • Page 79 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. See "Documentation of aircraft manufacturer" 24-30-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 9 July 01/2012...
  • 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 Kapitel 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 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 899788 Effectivity: 912 i Series 37-10-00 Edition 1/Rev. 0 Page 3 July 01/2012...
  • 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 Fig. 2 REMOVAL VACUUM PUMP - REMOVAL Preparation - General visual inspection. See relevant Main- tenance Manual Line for the 912 i Series engine type. - Carry out a functional test run to identify any damage. See "Documentation of aircraft manufacturer"...
  • Page 88 276332. NOTE: The needle sleeve, oil seal and ball bearing are damaged by this and must be replaced. 1. Insertion jig assy. part no. 276332 Effectivity: 912 i Series 37-10-00 Edition 1/Rev. 0 Page 6 July 01/2012...
  • Page 89 5. Press-in mushroom part no. 6. Needle sleeve 877597 Step Procedure The needle sleeve is pressed in as far as it will go by turning the hex. screw clockwi- 37-10-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 7 July 01/2012...
  • Page 90 Place on the vacuum pump gear and fix the lubricated drive sleeve with the retaining tool part no. 242660. Secure M8x16 Allen screw with LOCTITE 648 and tighten it. Tightening torque 25 Nm (18.44 ft.lb.) Effectivity: 912 i Series 37-10-00 Edition 1/Rev. 0 Page 8 July 01/2012...
  • Page 91 Tightening torque 25 Nm (18.44 ft.lb.) Fig. 13 1. Vacuum pump 3. Attachment flange 2. Gasket 4. M6 stud Fig. 14 1. Vacuum pump 2. 6.4 lock washer 3. M6 hex. nut 37-10-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 9 July 01/2012...
  • 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 Kapitel 1 2. Governor Kapitel 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 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 Edition 1/Rev. 0 Page 3 July 01/2012...
  • 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 - 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 (0.55 in.) long with a normal screw head. line assy. 5. 8.4/15/6 distance sleeve 6. 8/M8 cable clamp 7. A8 lock washer 8. M8x25 hex. screw 9. Oil pump housing Effectivity: 912 i Series 61-20-00 Edition 1/Rev. 0 Page 6 July 01/2012...
  • Page 101 276332. NOTE: The needle sleeve and ball bear- ing are damaged by this and must be replaced. Fig. 5 1. M5x12 countersunk screw 2. Retaining washer 61-20-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 7 July 01/2012...
  • Page 102 Install the washer and nut on the rear. The roller bearing is pressed out together with the oil inlet flange by turning the hex. screw clockwise. Remove the O-rings. Effectivity: 912 i Series 61-20-00 Edition 1/Rev. 0 Page 8 July 01/2012...
  • Page 103 MAINTENANCE MANUAL INSPECTION Fig. 10 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...
  • Page 104 0.4331 in. 0.4339 in. renewed 3 only) Spigot dia. On oil inlet GB06 10.935 mm 10.960 mm actual flange (on version 3 0.4305 in. 0.4315 in. renewed only) 61-20-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 10 July 01/2012...
  • Page 105 243 and tighten it. Tightening torque 6 Nm (53.09 in.lb.) 1. Puller part no. 876489 2. Hex. screw 3. Washer 4. Hex. nut 5. Press-in mushroom part no. 6. Needle sleeve 877597 61-20-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 11 July 01/2012...
  • Page 106 Fig. 16 1. Extractor part no. 877615 2. Press-in mushroom part no. 877590 1. Oil inlet flange 2. O-ring 3. Roller bearing 3. M6 threaded bores Effectivity: 912 i Series 61-20-00 Edition 1/Rev. 0 Page 12 July 01/2012...
  • Page 107 Tightening torque 10 Nm (88.48 in. lb.). NOTICE WARNUNG 1. Retaining tool part no. 2. Drive sleeve Longer screws destroy the oil feed line flange. 242660 3. M8x16 Allen screw 4. Vacuum pump gear 61-20-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 13 July 01/2012...
  • Page 108 Secure the M8x1 plug screws with screw and LOCTITE 243. LOCTITE 243. Tightening torque 15 Nm (132.72 in.lb.) Fig. 24 Fig. 23 1. Governor flange 2. M8x1 plug screw Effectivity: 912 i Series 61-20-00 Edition 1/Rev. 0 Page 14 July 01/2012...
  • Page 109 SB-912-052 "Installation/ use of governors". Governors manufactured by NOTE: McCAULEY and WOODWARD can- not be installed in the 912 i Series engine type due to their length. NOTICE WARNUNG The gear-tooth system of the governor must...
  • Page 110 BRP-Powertrain MAINTENANCE MANUAL NOTES 61-20-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 16 July 01/2012...
  • Page 111 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 112 BRP-Powertrain MAINTENANCE MANUAL NOTES 71-00-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 2 July 01/2012...
  • Page 113 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. 0 Page 3 July 01/2012...
  • Page 114 BRP-Powertrain MAINTENANCE MANUAL Power plant 71-00-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 4 July 01/2012...
  • Page 115 See also section 12-20-00 Planned maintenance. Checking the engine for contamination and damage. See also section 05-00-00 Maintenance. Installation of the engine and its components. See also section 71-00-00 Power plant. Effectivity: 912 i Series 71-00-00 Edition 1/Rev. 0 Page 5 July 01/2012...
  • Page 116 Engine test run/functional test. See also section 12-20-00 Planned maintenance. General notes/remarks: (Please fill in using block capitals!) (Please fill in using block capitals!) Location: __________________ Date: __________________ Signature: _________________________ 71-00-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 6 July 01/2012...
  • Page 117 - When the engine is delivered, check that the the data on the delivery note. original ROTAX packaging is not damaged. Check the engine for damage or corro- - If the packaging is damaged, contact the sion.
  • Page 118 NOTICE WARNUNG 912 i Series aircraft engines for at least 12 months from the BRP Powertrain delivery date. Storage is possible for up to 12 months if the li- This warranty is subject to the following condi-...
  • Page 119 RETURN TO SERVICE SYSTEM DESCRIPTION DESCRIPTION OF DESIGN Return to service A ROTAX 912 i Series engine consists basically WARNUNG WARNING 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 120 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 121 The first number block of the serial number indi- cates the year of manufacture, the second is a Cyl. 3 Cylinder 3 consecutive number. Cyl. 4 Cylinder 4 e.g. serial number 06310 71-00-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 11 July 01/2012...
  • Page 122 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 123 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 124 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. Connection for fuel feed line 71-00-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 14 July 01/2012...
  • Page 125 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 126 (labelled LANE A, LANE B) of the fuse box. 3. Controller connector A NOTE: Loosen the connector cap nut anti-clockwise. Pull the connectors in the two grooves out of the connector socket. Effectivity: 912 i Series 71-00-00 Edition 1/Rev. 0 Page 16 July 01/2012...
  • Page 127 3. Connector (fuel pump 1) 4. Connector (fuel pump 2) Fig. 13 1. M5x12 Allen screws 2. LANE IN 3. LANE OUT 1. Connector (fuel pump 1) 2. Screwdriver 71-00-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 17 July 01/2012...
  • Page 128 Effectivity: 912 i Series 71-00-00 Edition 1/Rev. 0 Page 18 July 01/2012...
  • Page 129 Completely loosen the screw connections between the engine suspension and the fire wall. Lift the engine out of the aircraft, clean it and prepare it. 71-00-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 19 July 01/2012...
  • Page 130 Using the crane or a similar lifting gear, position the engine slowly and carefully on the installation points of the engine suspension frame fastening on the fire wall of the aircraft. Effectivity: 912 i Series 71-00-00 Edition 1/Rev. 0 Page 20 July 01/2012...
  • Page 131 Remove the lifting gear. Fig. 17 1. Suspension points 71-00-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 21 July 01/2012...
  • Page 132 1. Engine suspension frame 2. M10x35 Allen screw 3. DIN 128-A10 lock washer 4. M10x35 Allen screw 3. Temperature sensor 4. EGT temperature sensor 5. 10.1/20/0.5 thrust washer (coolant) Effectivity: 912 i Series 71-00-00 Edition 1/Rev. 0 Page 22 July 01/2012...
  • Page 133 50% detached. If they are completely 1. Engine suspension frame 2. M10x35 Allen screw detached, immediate replacement is necessary. 71-00-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 23 July 01/2012...
  • Page 134 M10x110 and M10x35 hex screws is 40 Nm (353.92 in. lb.) FINISHING WORK - Install the water pump. See section 75-00-00. - Install the coolant hoses. See section 75-00- Effectivity: 912 i Series 71-00-00 Edition 1/Rev. 0 Page 24 July 01/2012...
  • Page 135 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 136 BRP-Powertrain MAINTENANCE MANUAL Engine 72-00-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 2 July 01/2012...
  • Page 137 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 138 BRP-Powertrain MAINTENANCE MANUAL NOTES 72-00-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 4 July 01/2012...
  • Page 139 BRP-Powertrain 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 140 BRP-Powertrain MAINTENANCE MANUAL Location on the engine 72-10-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 2 July 01/2012...
  • Page 141 Insertion jig 876518 SERVICE PRODUCTS Description Part no. Engine oil n.a. LOCTITE 243 897651 LOCTITE 648 899788 LOCTITE 5910 899791 LOCTITE 7063 n.a. KLUEBER ISOFLEX TOPAS Nb 5051 898351 Effectivity: 912 i Series 72-10-00 Edition 1/Rev. 0 Page 3 July 01/2012...
  • Page 142 BRP-Powertrain MAINTENANCE MANUAL Components 72-10-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 4 July 01/2012...
  • Page 143 - Engine cleaning. See relevant Maintenance During work on the engine there is a risk of life- Manual Line for the 912 i Series engine type. threatening injuries from the propeller and rotating parts in the engine! - Carry out an engine test run. See relevant...
  • Page 144 The gears are in pairs and must not be mixed up! 1. Puller part no. 877660 2. Handle 3. Gear cover Effectivity: 912 i Series 72-10-00 Edition 1/Rev. 0 Page 6 July 01/2012...
  • Page 145 Push the dog gear down only until the ring hal- ves can be taken out, otherwise the gearbox housing can be damaged. The gear cover must be freely rotatable! 1. Bearing bushing 2. Propeller shaft 72-10-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 7 July 01/2012...
  • Page 146 2. M24x1.5 hex. nut Place the gearbox housing on a suitable 3. Press-out mushroom 4. Propeller shaft support. Press out the propeller shaft with an ex- tractor part no. 877615. Effectivity: 912 i Series 72-10-00 Edition 1/Rev. 0 Page 8 July 01/2012...
  • Page 147 3. Ball bearing 6207 E 4. 36/50/5.5 radius ring THNC3 5. Oil seal AS 40x55x7 FPM REMOVAL OF THE ROLLER BEARING, VERSION 3 See also section 61-20-00 Governor. 72-10-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 9 July 01/2012...
  • Page 148 Check the axial runout of the propel- ler flange. See section 72-10-00 Wear limits. Check the oil seal running surface. 1. Flat sealing surfaces 2. Contact surfaces Effectivity: 912 i Series 72-10-00 Edition 1/Rev. 0 Page 10 July 01/2012...
  • Page 149 1. Oil seal running surface 2. Groove for retaining rings 3. Gear-tooth system 4. Propeller shaft 5. Propeller flange 72-10-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 11 July 01/2012...
  • Page 150 72-10-00 Wear limits. (GB11) Check the heat-treated steel bearing bushing for wear. 1. Step collar 2. Disc springs Effectivity: 912 i Series 72-10-00 Edition 1/Rev. 0 Page 12 July 01/2012...
  • Page 151 As well as the material and the heat treatment of it, the surface quality and structure, surface treatment and lubricant (visco- sity at operating temperature and additives) are also important. 72-10-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 13 July 01/2012...
  • Page 152 If in doubt, cant and amount of stress. The pitting surface consult technical literature or contact can become so large that the remaining unda- the authorised ROTAX distributor or its service centre. maged flank can no longer transfer the load. Fig. 17 Fig.
  • Page 153 (greatest longitudinal extent) of 0.5 mm. Pit formation in the dedendum region of a spur gear tooth Otherwise the gear set must be replaced system Magnification approx. 1.5x. 72-10-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 15 July 01/2012...
  • Page 154 This pattern of damage generally occurs at low operating oil viscosities and/or high oil tempera- tures. Apart from these, the same causes apply as for pitting. Triangular flake pitting Magnification approx. 2x. Effectivity: 912 i Series 72-10-00 Edition 1/Rev. 0 Page 16 July 01/2012...
  • Page 155 BRP-Powertrain MAINTENANCE MANUAL WEAR LIMITS Fig. 24 Effectivity: 912 i Series 72-10-00 Edition 1/Rev. 0 Page 17 July 01/2012...
  • Page 156 0.0394 in. 0.0408 in. replaced Total height of disc GB13 5.20 mm 5.40 mm 4.80 mm 5.00 mm current spring 0.2047 in. 0.2126 in. 0.1889 in. 0.1968 in. replaced 72-10-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 18 July 01/2012...
  • Page 157 Pitting on dog gear 2.5% current up to 5% replaced Gear backlash GB18 0.07 mm 0.15 mm 0.20 mm 0.18 mm current 0.0028 in. 0.0059 in. 0.0079 in. 0.0069 in. replaced Effectivity: 912 i Series 72-10-00 Edition 1/Rev. 0 Page 19 July 01/2012...
  • Page 158 0.0039 in. replaced Crankshaft Measure crankshaft CS24 0.000 mm 0.060 mm 0.080 mm current run-out (installed in 0.0000 in. 0.0024 in. 0.0031 in. replaced housing with drive gear) 72-10-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 20 July 01/2012...
  • Page 159 Push or press on, do not tap on. 09584 1. M7x16 hex. screw 2. 7.2/18.8/3 washer 3. Ball bearing 6207 E THNC3 4. 36/50/5.5 radius ring 5. Oil seal AS 40x55x7 FPM 72-10-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 21 July 01/2012...
  • Page 160 11. Inner ring 12. Sleeve 3. Step collar 4. Disc springs 5. Clutch assy. Step Procedure Install the lubricated bearing bushing carefully on the propeller shaft with circlip pliers. Effectivity: 912 i Series 72-10-00 Edition 1/Rev. 0 Page 22 July 01/2012...
  • Page 161 (propeller shaft) cannot be pressed down 3. Drive gear enough to insert the ring halves. Do not increase the force, but remove the clutch again and cen- ter the disc springs correctly. 72-10-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 23 July 01/2012...
  • Page 162 Press down the gear (propeller shaft) with a mounting yoke part no. 876885 and as- semble with new ring halves. Fig. 33 1. Mounting yoke 2. Ring halves Part no. 876885 Effectivity: 912 i Series 72-10-00 Edition 1/Rev. 0 Page 24 July 01/2012...
  • Page 163 Insert 2 6x20 dowel pins into the crank- case. Hold the roller bearing rollers in position with KLUEBER ISOFLEX TOPAS Nb5051 and lubricate the bearing position of the propeller shaft and crankshaft. 72-10-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 25 July 01/2012...
  • Page 164 Tap gently on the gearbox housing with a - Carry out an engine test run. See relevant soft-faced hammer to position the gear- box on the crankcase. Maintenance Manual Line for the 912 i Series engine type. NOTE: If there is a large amount of re-...
  • Page 165 BRP-Powertrain MAINENANCE 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 166 BRP-Powertrain MAINENANCE MANUAL NOTES 72-20-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 2 July 01/2012...
  • Page 167 38x20 insert for SW32 hex. nut, magneto side 876070 crankshaft A 20x12.5 reducing socket 877460 Protection mushroom 876557 SERVICE PRODUCTS Description Part no. Klueber ISOFLEX TOPAS NB5051 898351 LOCTITE 7063 898450 LOCTITE 603 899789 Effectivity: 912 i Series 72-20-00 Edition 1/Rev. 0 Page 3 July 01/2012...
  • Page 168 BRP-Powertrain MAINENANCE MANUAL Engine block 72-20-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 4 July 01/2012...
  • Page 169 Manual Line for the 912 i Series engine type. - Engine cleaning. See relevant Maintenance Manual Line for the 912 i Series engine type. - Carry out an engine test run. See relevant Maintenance Manual Line for the 912 i Series engine type.
  • Page 170 The sprag clutch housing should be disassem- 3. End of crankshaft bled on a clean surface. There must be enough space to lay out the removed parts to ensure Effectivity: 912 i Series 72-20-00 Edition 1/Rev. 0 Page 6 July 01/2012...
  • Page 171 Fig. 7 Fig. 8 1. Sprag clutch housing 2. Sprag clutch 1. Oil nozzle 2. Cone surface 3. Circlip 3. Sprag clutch engagement face 72-20-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 7 July 01/2012...
  • Page 172 1. Helical spring 2. Spear body FREE WHEEL GEAR CHECK Step Procedure Check the gear-tooth system of the free wheel gear. 1. Intermediate gear shaft 2. Starter intermediate gear Effectivity: 912 i Series 72-20-00 Edition 1/Rev. 0 Page 8 July 01/2012...
  • Page 173 To assemble it, compress it slightly NOTE: with Seeger ring pliers and ensure that the Seeger ring remains in posi- tion and latches completely with the noses in the sprag clutch body. 72-20-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 9 July 01/2012...
  • Page 174 BRP-Powertrain MAINENANCE MANUAL NOTES 72-20-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 10 July 01/2012...
  • Page 175 BRP-Powertrain MAINENANCE 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 176 KLUEBER ISOFLEX TOPAS. Install the starter intermediate gear. Install the intermediate gear shaft. Fig. 19 1. Intermediate gear shaft 2. Starter intermediate gear Effectivity: 912 i Series 72-20-00 Edition 1/Rev. 0 Page 12 July 01/2012...
  • Page 177 - Fill with operating fluids or check filling levels. See relevant Maintenance Manual Line for the 912 i Series engine type. - Carry out an engine test run. See relevant Maintenance Manual Line for the 912 i Series engine type.
  • Page 178 BRP-Powertrain MAINENANCE MANUAL NOTES 72-20-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 14 July 01/2012...
  • Page 179 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 180 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 181 Valve spring mounting device 877380 Torx T30 ball-head insert 876180 Collet n.a. SERVICE PRODUCTS Description Part no. KLUEBER ISOFLEX TOPAS NB5051 898351 LOCTITE 648 899788 Engine oil n.a. Effectivity: 912 i Series 72-30-00 Edition 1/Rev. 0 Page 3 July 01/2012...
  • Page 182 BRP-Powertrain MAINTENANCE MANUAL Cylinder head 72-30-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 4 July 01/2012...
  • Page 183 - Carry out an engine test run. See relevant Maintenance Manual Line for the 912 i Series engine type. - Engine cleaning. See relevant Maintenance Manual Line for the 912 i Series engine type. 1. Exhaust system 2. Fuel hose assy. 3. Intake manifold 4.
  • Page 184 (inlet). See also section 75-00-00 Cooling system. There is an O-ring under the elbow NOTE: flange. Remove the connector brackets on cylinder 3/4. Effectivity: 912 i Series 72-30-00 Edition 1/Rev. 0 Page 6 July 01/2012...
  • Page 185 Loosen the M6x30 screw and washer. Remove the valve cover with the large and small O-rings. Fig. 6 1. M6x30 screw 2. 6.0 washer 3. Valve cover 4. O-rings 72-30-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 7 July 01/2012...
  • Page 186 Mark the installation position of the NOTE: push-rod with an appropriate marker (e.g. a touch-up pen) (e.g. "IV1" for in- take valve cylinder 1). Effectivity: 912 i Series 72-30-00 Edition 1/Rev. 0 Page 8 July 01/2012...
  • Page 187 1. Cylinder head assy. 2. Valve spring collet 1. Rocker arm shaft 2. Right rocker arm 3. Valve spring mounting 4. Valve cotter 3. Left rocker arm device part no. 877380 72-30-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 9 July 01/2012...
  • Page 188 Loosen 2 M6x20 Allen screws with 6.4 Preparation washer. - General visual inspection. See relevant Main- Remove the elbow flange and O-ring. tenance Manual Line for the 912 i Series Remove the connector brackets on NOTE: engine type. cylinder 3/4.
  • Page 189 Step Procedure Inspect the cone of the exhaust manifold. Indentations and scratches no greater than 0.2 mm are permissible. Bumps no greater than 0.1 mm are per- missible. 72-30-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 11 July 01/2012...
  • Page 190 If the engine has been overheated, a hardness Fig. 15 test of the cylinder head is necessary. See the current Maintenance Manual Line for the 912 i Series engine type. The hardness test takes place at measurement point CH08 according to Fig.
  • Page 191 Oil residues up to max. 20 % of the running sur- face are permissible. At greater values, the valve may have already been overheated and must be replaced. Risk of 06448 valve fracture at the weld point. 72-30-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 13 July 01/2012...
  • Page 192 If there are burn marks or distortion, the cylinder head must be sent to an authorised overhauling Step Procedure company for overhauling or repair. Check the valve springs visually for dam- age such as fracture, deformation. Effectivity: 912 i Series 72-30-00 Edition 1/Rev. 0 Page 14 July 01/2012...
  • Page 193 The rocker arms for the inlet and outlet Fig. 24 are different. 06453 1. Measurement region 72-30-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 15 July 01/2012...
  • Page 194 Fig. 28 cker arm bearing in the cylinder head. 1. Rocker arm bushing 2. Groove Effectivity: 912 i Series 72-30-00 Edition 1/Rev. 0 Page 16 July 01/2012...
  • Page 195 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 196 BRP-Powertrain MAINTENANCE MANUAL 06459 72-30-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 18 July 01/2012...
  • Page 197 0.4760 in. 0.4746 in. replaced arm shaft Exhaust CH05 12.000 mm 12.018 mm 12.090 mm 12.054 mm current Valve 0.4724 in. 0.4731 in. 0.4760 in. 0.4746 in. replaced Effectivity: 912 i Series 72-30-00 Edition 1/Rev. 0 Page 19 July 01/2012...
  • Page 198 0.0039 in. 0.0079 in. 0.0059 in. replaced Push-rod Exhaust VT09 0.000 mm 0.100 mm 0.200 mm 0.150 mm current Valve 0.0000 in. 0.0039 in. 0.0079 in. 0.0059 in. replaced 72-30-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 20 July 01/2012...
  • Page 199 Secure the coolant elbow with LOCTITE 243 and install the elbow in the cold cylin- der head. NOTE: Also lubricate the thread in the cylinder head with LOCTITE 243. 72-30-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 21 July 01/2012...
  • Page 200 3. Valve spring retainer 4. Valve stem seal 3. Elbow flange 4. 19x2 O-ring Step Procedure 5. Cable brackets Install the valve springs and the valve spring retainer Effectivity: 912 i Series 72-30-00 Edition 1/Rev. 0 Page 22 July 01/2012...
  • Page 201 Carry out the same procedure for the ex- haust valve. Fig. 35 1. Rocker arm shaft 2. Rocker arm 1. Valve cotter 2. Mounting device 3. Collet 72-30-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 23 July 01/2012...
  • Page 202 BRP-Powertrain MAINTENANCE MANUAL NOTES 72-30-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 24 July 01/2012...
  • Page 203 2 M8 collar cap nuts and 2 M8 hex. nuts. 1. Push-rods 2. Oil return tubes If necessary, repeat the process for NOTE: 3. 16x5 O-ring the other cylinder heads. 72-30-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 25 July 01/2012...
  • Page 204 Fasten the elbow flange with 2 M6x20 Al- len screws and 6.4 lock washers. Tightening torque 10 Nm (88.48 in. lb.). 1. Insulating flange 2. M6x20 hex./torx collar screw 3. Intake manifold Effectivity: 912 i Series 72-30-00 Edition 1/Rev. 0 Page 26 July 01/2012...
  • Page 205 M6 hex. nut and 6.4 washer. - Install the fuel line assy. To do this, see sec- tion 73-10-00 Fuel pump and distribution. - Install the exhaust system. See also section 78-00-00 Exhaust. 72-30-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 27 July 01/2012...
  • Page 206 Tightening torque 10 Nm (88.48 in. lb.) loose or the valve cover leaks, the oil return to +180°. the oil tank works by "blow by gas" i.e. in- sufficiently. Effectivity: 912 i Series 72-30-00 Edition 1/Rev. 0 Page 28 July 01/2012...
  • Page 207 1. M6x30 Allen screw 2. 6/12/1 washer 78-00-00 Exhaust. 3. Cylinder head cover 4. 6.4x1.8 O-ring - Connect the wiring harness. See also section 5. 105x2.5 O-ring 76-00-00 Wiring harness. 72-30-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 29 July 01/2012...
  • Page 208 BRP-Powertrain MAINTENANCE MANUAL NOTES 72-30-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 30 July 01/2012...
  • Page 209 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 210 BRP-Powertrain MAINTENANCE MANUAL 72-30-10 Effectivity: 912 i Series Edition 1/Rev. 0 Page 2 July 01/2012...
  • Page 211 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. Effectivity: 912 i Series 72-30-10 Edition 1/Rev. 0 Page 3 July 01/2012...
  • Page 212 BRP-Powertrain MAINTENANCE MANUAL NOTES 72-30-10 Effectivity: 912 i Series Edition 1/Rev. 0 Page 4 July 01/2012...
  • Page 213 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 214 Fig. 3 1. mono hook circlip remover 2. Hydraulic valve tappet 1. Piston pin puller 2. Puller spindle 3. Pistons Effectivity: 912 i Series 72-30-10 Edition 1/Rev. 0 Page 6 July 01/2012...
  • Page 215 Fig. 5 1. Pistons 2. Ring grooves 3. Feeler gauge 1. Piston rings 2. Ring grooves 3. Piston crown 4. Piston pin circlip groove 72-30-10 Effectivity: 912 i Series Edition 1/Rev. 0 Page 7 July 01/2012...
  • Page 216 PISTON PIN - INSPECTION contact is achieved. NOTICE WARNUNG The mono hook circlips for the axial piston pin circlip must only be used once and must therefo- re be replaced. Effectivity: 912 i Series 72-30-10 Edition 1/Rev. 0 Page 8 July 01/2012...
  • Page 217 Check visually for damage and wear. NOTE: The hydraulic valve tappet rota- tes during operation, so there is a uniform, rotationally symmetri- cal support pattern on the cam contact face. 72-30-10 Effectivity: 912 i Series Edition 1/Rev. 0 Page 9 July 01/2012...
  • Page 218 BRP-Powertrain MAINTENANCE MANUAL WEAR LIMITS 72-30-10 Effectivity: 912 i Series Edition 1/Rev. 0 Page 10 July 01/2012...
  • Page 219 BRP-Powertrain MAINTENANCE MANUAL Effectivity: 912 i Series 72-30-10 Edition 1/Rev. 0 Page 11 July 01/2012...
  • Page 220 PI05 0.030 mm 0.062 mm 0.100 mm 0.081 mm current ween piston 0.0012 in. 0.0024 in. 0.0039 in. 0.0032 in. replaced ring groove and conical compression ring 2 72-30-10 Effectivity: 912 i Series Edition 1/Rev. 0 Page 12 July 01/2012...
  • Page 221 0.0012 in. 0.0024 in. 0.0018 in. replaced Post-machi- 0.0000 mm 0.0000 mm 0.03 mm current ning of 0.0000 in. 0.0000 in. 0,0012 in. replaced sealing sur- face/cylinder head Effectivity: 912 i Series 72-30-10 Edition 1/Rev. 0 Page 13 July 01/2012...
  • Page 222 BRP-Powertrain MAINTENANCE MANUAL NOTES 72-30-10 Effectivity: 912 i Series Edition 1/Rev. 0 Page 14 July 01/2012...
  • Page 223 Step Procedure rotate in the crankcase without resistance. Install the piston in accordance with the following figures. NOTE: The eccentricity of the piston pin bore is 1 mm. 72-30-10 Effectivity: 912 i Series Edition 1/Rev. 0 Page 15 July 01/2012...
  • Page 224 BRP-Powertrain MAINTENANCE MANUAL Fig. 13 72-30-10 Effectivity: 912 i Series Edition 1/Rev. 0 Page 16 July 01/2012...
  • Page 225 Push the installation tool into the position gauge and press the ring forwards as far as it will go. 1. Piston pin puller 2. Puller spindle 3. Extracting nut 4. Piston pin 5. Pistons 72-30-10 Effectivity: 912 i Series Edition 1/Rev. 0 Page 17 July 01/2012...
  • Page 226 Support the piston with your hand and push the mono hook circlip into the retaining groove of the piston with a st- rong pressure on the installation tool. Effectivity: 912 i Series 72-30-10 Edition 1/Rev. 0 Page 18 July 01/2012...
  • Page 227 Before commissioning, take note of NOTE: The ring gap should never come to lie in the SI-912-018 Purging of lubrication sys- region of the piston pin eye. tem. 72-30-10 Effectivity: 912 i Series Edition 1/Rev. 0 Page 19 July 01/2012...
  • Page 228 BRP-Powertrain MAINTENANCE MANUAL NOTES 72-30-10 Effectivity: 912 i Series Edition 1/Rev. 0 Page 20 July 01/2012...
  • Page 229 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 230 BRP-Powertrain MAINTENANCE MANUAL NOTES 73-00-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 2 July 01/2012...
  • Page 231 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 232 FUEL FILTER Coarse filter CONNECTIONS FOR DISPLAY SYSTEMS The coarse filter is installed by the aircraft manu- facturer and is not included in the ROTAX deli- NOTICE WARNUNG very. Fine filter Follow the instructions in the installation manual regarding connections for instrumentation.
  • Page 233 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 234 Page 31 D. Throttle body assy. - installation Page 32 E. Airbox - installation Page 33 F. Fuel line assy. - installation Page 34 10. Finishing work Page 35 73-10-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 2 July 01/2012...
  • Page 235 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 236 BRP-Powertrain MAINTENANCE MANUAL Fuel distribution 73-10-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 4 July 01/2012...
  • Page 237 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 238 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. (differential fuel pressure). The injection quantity...
  • Page 239 Danger of severe burns and scalds! Always - General visual inspection. See relevant Main- allow the engine to cool down to ambient tem- tenance Manual Line for the 912 i Series perature before starting any work. engine type. - Carry out an engine test run. See relevant...
  • Page 240 Loosen 2 M12x1.5 banjo bolts with gasket Remove the cable ties and pull out the ring. hose. Remove the fuel line assy. Disconnect the plug connection to the temperature sensor. Effectivity: 912 i Series 73-10-00 Edition 1/Rev. 0 Page 8 July 01/2012...
  • Page 241 2. Gasket ring 3. Pressure regulator housing Step Procedure Loosen the M5 Allen screws. NOTE: 1 M5x35 Allen screw. 1 M5x45 Allen screw. Remove the fuel pressure regulator and housing. 73-10-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 9 July 01/2012...
  • Page 242 1. Retaining ring 2. Fuel pressure regulator 1. Cable ties 2. Hose 3. Temperature sensor Step Procedure Remove the retaining ring using Seeger ring pliers. Remove the fuel pressure regulator. Effectivity: 912 i Series 73-10-00 Edition 1/Rev. 0 Page 10 July 01/2012...
  • Page 243 For cylinder 2 and cylinder 4, loosen the fuel pressure regulator and the M5x35 Allen screw. Lift off the heat shield on both sides in the region of the rivet nut. 73-10-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 11 July 01/2012...
  • Page 244 INJ_1 to INJ_8. after the connector has been disconnected so that it does Fig. 13 not get lost. Fig. 14 1. Injector connectors 1. Injector connectors 2. Screwdriver Effectivity: 912 i Series 73-10-00 Edition 1/Rev. 0 Page 12 July 01/2012...
  • Page 245 - Remove the injection valves from the fuel rails - Remove the fuel pressure regulator assy. IGNITION COIL - REMOVAL Step Procedure Remove the cable clamps of the wiring harness. 73-10-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 13 July 01/2012...
  • Page 246 Carefully pull EGT 1 and EGT 2 (cylinders Remove the double ignition coils 1 and 2) out of the locking plate. Press the metal bracket and unplug the connectors. Effectivity: 912 i Series 73-10-00 Edition 1/Rev. 0 Page 14 July 01/2012...
  • Page 247 4 hex./torx collar sc- rews. NOTE: The intake manifolds have ports rather than bores for the M6 hex./torx collar screws. 73-10-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 15 July 01/2012...
  • Page 248 76-50-00 Wiring harness. - Loosen and detach the wiring harness (main strand) from all fastenings (cable ties, retaining fixtures) on the engine. See also section 76-50-00 Wiring harness. Effectivity: 912 i Series 73-10-00 Edition 1/Rev. 0 Page 16 July 01/2012...
  • Page 249 Fig. 29 washer. Fig. 27 1. Nipple 2. Gasket ring 3. M6x12 hex. screw 1. M6 hex. nut 2. 6.4 washer 73-10-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 17 July 01/2012...
  • Page 250 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 251 - Drain the fuel from the fuel pump and close it Dispose of operating fluids in an eco-friendly with appropriate plug caps. manner! Overview: 1. Housing 2. Intake system 3. Pressure line 4. Fuel pump assy. Effectivity: 912 i Series 73-10-00 Edition 1/Rev. 0 Page 19 July 01/2012...
  • Page 252 1. M6 hex. nut 2. Housing 3. Fuel pump unit 1. Main pump (main) 2. Additional pump (aux) 3. Connector (Fuel pump 1) 4. Connector (Fuel pump 2) Effectivity: 912 i Series 73-10-00 Edition 1/Rev. 0 Page 20 July 01/2012...
  • Page 253 The roughness depth of the flat surfaces be replaced. O-rings are not must not be changed! available as spare parts. Check the screen for dirt. 73-10-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 21 July 01/2012...
  • Page 254 Scuffing marks (including scratches) on the valves are permissible up to a maxi- mum depth of 0.2 mm (0.0079 in.). 1. Fuel rail 2. Sealing surface for O-rings Effectivity: 912 i Series 73-10-00 Edition 1/Rev. 0 Page 22 July 01/2012...
  • Page 255 Bumps up to a maximum of 0.1 mm (0.0039 in.) are permissible. Fig. 44 1. Airbox 2. Support plate 3. Connecting piece 4. Threaded bores 1. Contact face 73-10-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 23 July 01/2012...
  • Page 256 Fig. 46 Fig. 47 1. Throttle valve assy. 2. Throttle shaft 1. Fuel pump assy. 3. Throttle valve 4. Throttle cable 5. Rubber gasket ring Effectivity: 912 i Series 73-10-00 Edition 1/Rev. 0 Page 24 July 01/2012...
  • Page 257 Install the fuel line assy. NOTE: The position and type of positioning and attachment of the fuel pump depends on the aircraft type. See aircraft manufactu- rer documentation. 73-10-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 25 July 01/2012...
  • Page 258 When the retaining ring is moun- ted, it must be possible to rotate the fuel pressure regulator ma- nually. Fig. 50 1. Nipple 2. Gasket rings 3. Hex. screw 1. Fuel pressure regulator Effectivity: 912 i Series 73-10-00 Edition 1/Rev. 0 Page 26 July 01/2012...
  • Page 259 Fix the 2/4, 1/3 intake manifolds with 8 M6x20 hex./torx collar screws from the in- side outwards. Tightening torque 10 Nm (88.48 in. lb.). Install new 1-ear clamps. 73-10-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 27 July 01/2012...
  • Page 260 Fig. 56 lock washers. Tightening torque 6 Nm (53 in. lb.). Fig. 58 1. 1-ear clamp 2. Intake manifold 1. M5x16 Allen screw 2. 5.3 washer 3. Plug holder Effectivity: 912 i Series 73-10-00 Edition 1/Rev. 0 Page 28 July 01/2012...
  • Page 261 When a used injection jet is re- installed, new O-rings must be 1. Ignition coil connector 2. Double ignition coils installed, and the injection jet must be inserted by hand. 3. EGT connector 73-10-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 29 July 01/2012...
  • Page 262 Procedure Tightening torque 6 Nm (53 in. lb.) Fasten the heat shield with 4 M5x12 Allen screws and 5.3 lock washers. Tightening torque 6 Nm (53 in. lb.) Effectivity: 912 i Series 73-10-00 Edition 1/Rev. 0 Page 30 July 01/2012...
  • Page 263 3. Heat shield 4. M5x35 Allen screw Step Procedure Install the cover with an M5x12 Allen screw and 5.3 lock washer. Tightening torque 5 Nm (44.25 in. lb.) 73-10-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 31 July 01/2012...
  • Page 264 3. Fuel pressure regulator assy. Step Procedure Fix hose 60 (regulator/airbox) with 1. Throttle body assy. 2. Rubber gasket ring 2 cable ties. Plug in temperature sensor CTS. Effectivity: 912 i Series 73-10-00 Edition 1/Rev. 0 Page 32 July 01/2012...
  • Page 265 Fix the 1-ear clamps. Fig. 76 1. Throttle body assy. 2. EGT connector 3. Air filter 4. Screw hose clamp 1. M6 DIN 924 hex. nut 2. 6.4 washer 73-10-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 33 July 01/2012...
  • Page 266 M6x16 Allen screw and 6.4 washer to the 3. 203x7.6mm cable ties 4. 142x3.2mm cable ties propeller gearbox with LOCTITE 243. Tightening torque 10 Nm (88.48 in. lb.). Effectivity: 912 i Series 73-10-00 Edition 1/Rev. 0 Page 34 July 01/2012...
  • Page 267 2. 6.4 washer 3. 8/M6 cable clamp Step Procedure Install the inlet and outlet lines on the 1/3 and 2/4 fuel rails. Fig. 81 1. Inlet line 2. Outlet line 73-10-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 35 July 01/2012...
  • Page 268 BRP-Powertrain MAINTENANCE MANUAL NOTES 73-10-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 36 July 01/2012...
  • Page 269 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 270 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 271 Follow the general safety instructions during all work on the engine and the assemblies around it. See section Introduction. See also section 70-00-00 Standard work on the engine. 74-00-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 3 July 01/2012...
  • Page 272 BRP-Powertrain MAINTENANCE MANUAL NOTES 74-00-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 4 July 01/2012...
  • Page 273 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 274 BRP-Powertrain WARTUNGSHANDBUCH Distribution 74-20-00 Effectivity: 912 i Series Edition 1/Rev. 0 Seite 2 July 01/2012...
  • Page 275 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 276 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 277 FUSE BOX FUSE BOX Generator A Generator A SP 1 SP 1 LANE A LANE A LANE A LANE A SP 3 SP 3 Regler A Regler A 09728 Effectivity: 912 i Series 74-20-00 Edition 1/Rev. 0 Page 5 July 01/2012...
  • Page 278 BRP-Powertrain MAINTENANCE MANUAL NOTES 74-20-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 6 July 01/2012...
  • Page 279 The cables are only available as comple- NOTE: NOTICE WARNUNG te parts (ignition cable, protection hose, ignition coil side connector). Follow the instructions in the installation manual regarding connections for instrumentation. 74-20-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 7 July 01/2012...
  • Page 280 2. Lock washer - Engine cleaning. See relevant Maintenance 3. Cable clamp Manual Line for the 912 i Series engine type. - Carry out an engine test run. See relevant Fig. 3 Maintenance Manual Line for the 912 i Series...
  • Page 281 If this proves difficult, push down with a hex. socket wrench or similar. Do not use a sharp tool! 1. M5x16 Allen screw 2. A5 lock washer 3. Cable holder 74-20-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 9 July 01/2012...
  • Page 282 76-50-00 Wiring harness. The knock sensor must only be removed NOTE: if necessary! Fig. 9 1. Cable ties 2. Ignition coils 3. Resistance spark plug 4. Ignition cable assy. connector Effectivity: 912 i Series 74-20-00 Edition 1/Rev. 0 Page 10 July 01/2012...
  • Page 283 Check double ignition coils for damage, corrosion and deformation. Check contact faces: Indentations up to a max. of 0.5 mm (0.0197 in.). Bumps up to a max. of 0.5 mm (0.0197 in.). 74-20-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 11 July 01/2012...
  • Page 284 See also section 74-20-00 Wear limits. Fig. 13 1. Spark plug 2. Feeler gauge KNOCK SENSOR (KNOCK) - INSPECTION To do this, see section 76-70-00 Sensors and actuators. Effectivity: 912 i Series 74-20-00 Edition 1/Rev. 0 Page 12 July 01/2012...
  • Page 285 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. 0 Page 13 July 01/2012...
  • Page 286 1. Resistance spark plug 2. Ignition cable assy. connector 3. 94x2.5 cable ties Step Procedure Route the ignition cable assy. correctly and secure it with a cable tie. Effectivity: 912 i Series 74-20-00 Edition 1/Rev. 0 Page 14 July 01/2012...
  • Page 287 EGT connector so that the spring clip latches in. Fig. 18 1. Double ignition coils 2. Ignition coil connector (coil 1, coil 2, coil 3, coil 4) 1. EGT connector 2. Connector 74-20-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 15 July 01/2012...
  • Page 288 Leaking Allen screws can cause an excessively lean mixture! Step Procedure Secure the 12/M6 cable clamp with an M6x14 Allen screw and washer with LOC- TITE 243. Tightening torque 10 Nm (88.48 in. lb.). Effectivity: 912 i Series 74-20-00 Edition 1/Rev. 0 Page 16 July 01/2012...
  • Page 289 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 290 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 291 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. 0 Page 3 July 01/2012...
  • Page 292 BRP-Powertrain MAINTENANCE MANUAL Cooling system 75-00-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 4 July 01/2012...
  • Page 293 NOTICE WARNUNG RADIATOR Follow the instructions in the installation manual See the current 912 i Series Installation Manual. regarding connections for instrumentation. For more detailed information on operation, maintenance, safety or flight, consult the docu- TEMPERATURE SENSOR mentation provided by the aircraft manufacturer Coolant flows around the temperature sensor, and dealer.
  • Page 294 Loosen 4 Allen screws on the intake man- - Engine cleaning. See relevant Maintenance ifold (cyl. 2/4). See section 73-10-00. Manual Line for the 912 i Series engine type. Remove the intake manifold (cyl. 2/4) with REMOVAL all its attached parts.
  • Page 295 Step Procedure Take off the spring type hose clip using spring clamp pliers part no. 877840. Remove the preformed hose from the coolant elbow with a suitable tool. 75-00-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 7 July 01/2012...
  • Page 296 877840 and detach the coolant hoses from the water pump housing. The water pump housing and gasket can be removed by loosening the other 5 M6 screws. Effectivity: 912 i Series 75-00-00 Edition 1/Rev. 0 Page 8 July 01/2012...
  • Page 297 Press out the old oil seal and the rotary 1. Impeller 2. 8.2/12.5/1.5 washer seal with two bolts and a suitable jig. NOTE: The diameter of the bolt is 5 mm (0.1969 in.). 75-00-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 9 July 01/2012...
  • Page 298 2. Coolant elbow with a suitable tool. 3. Thread Remove the rubber plate. Fig. 12 1. Expansion tank 2. Rubber plate 3. Preformed hoses 4. Spring type hose clips Effectivity: 912 i Series 75-00-00 Edition 1/Rev. 0 Page 10 July 01/2012...
  • Page 299 Procedure Check the axial position of the water pump shaft and pump gear. NOTE: The wide collar of the gear 1. Expansion tank points inwards towards the crankcase. 75-00-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 11 July 01/2012...
  • Page 300 NOTE: If signs of contact are found, the water pump housing must be re- placed. Fig. 16 1. Feeler gauge 2. Water pump housing Effectivity: 912 i Series 75-00-00 Edition 1/Rev. 0 Page 12 July 01/2012...
  • Page 301 0.3366 in. 0.3484 in. 0.3484 in. replaced Distance from impel- WP02 0.3 mm 0.5 mm 0.7 mm 0.6 mm current 0.012 in. 0.020 in. 0.028 in. 0.024 in. replaced Effectivity: 912 i Series 75-00-00 Edition 1/Rev. 0 Page 13 July 01/2012...
  • Page 302 Insert the pump gear in the ignition hous- ing. 1. Ignition housing 2. Oil seal 3. Pump shaft 4. Rotary seal 5. Insertion jig Effectivity: 912 i Series 75-00-00 Edition 1/Rev. 0 Page 14 July 01/2012...
  • Page 303 Fig. 20 1. Water pump 2. 20° coolant elbow (blue) housing 3. 45° coolant elbow (red) 1. Impeller 2. 8.2/12.5/1.5 washer 75-00-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 15 July 01/2012...
  • Page 304 Push on preformed hose 3 and align it horizontally. 1. Preformed hose 2. Preformed hose connection 2 connection 1 3. Rubber plate 4. Preformed hose connection 4 Effectivity: 912 i Series 75-00-00 Edition 1/Rev. 0 Page 16 July 01/2012...
  • Page 305 25 so that it is 2 mm (0.0787 in.) away from the spring type hose clip on preformed hose 3. Push on preformed hose 1 and align it horizontally like preformed hose 3. 75-00-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 17 July 01/2012...
  • Page 306 Install the spring type hose clip 25 on pre- formed hose 2 and position it vertically. Push on preformed hose 2 and align it horizontally. NOTE: Preformed hose 2 is symmetri- cal. Effectivity: 912 i Series 75-00-00 Edition 1/Rev. 0 Page 18 July 01/2012...
  • Page 307 4. M6x35 Allen screw Position the expansion tank assy. with the 5. 6.4 washers 6. M6x35 Allen screw 5 preformed hoses on the engine. (stainless) 7. Gasket ring 75-00-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 19 July 01/2012...
  • Page 308 5. Spring type hose clip NOTE: Start with the shortest hose (preformed hose 2). Then pre- formed hose 1, then preformed hose 3 and pre- formed hose 4. Fig. 33 Effectivity: 912 i Series 75-00-00 Edition 1/Rev. 0 Page 20 July 01/2012...
  • Page 309 - Install the air filter with the heat shield. See the current Maintenance Manual Line. - Fill with coolant. See relevant Maintenance Manual Line for the 912 i Series engine type. - Bleed the engine cooling system. See rele- vant Maintenance Manual Line for the 912 i Series engine type.
  • Page 310 BRP-Powertrain MAINTENANCE MANUAL NOTES 75-00-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 22 July 01/2012...
  • Page 311 - 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 312 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 313 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 314 BRP-Powertrain MAINTENANCE MANUAL NOTES 76-10-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 2 July 01/2012...
  • Page 315 3) The y-cable must be according to the wiring diagram in Fig. 1. Fig. 1 CAN_LOW_LA/LB 2 CAN_LOW_LA CAN_LOW_LB CAN_GND_LA/LB 3 CAN_GND_LA CAN_GND_LB CAN_HIGH_LA/LB 7 CAN_HIGH_LA CAN_HIGH_LB D-SUB_DE9_MALE D-SUB_DE9_MALE D-SUB_DE9_FEMALE Lane A Lane B 09956 Effectivity: 912 i Series 76-10-00 Edition 1/Rev. 1 Page 3 October 01/2013...
  • Page 316 BRP-Powertrain MAINTENANCE MANUAL Control unit (ECU) 76-10-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 4 July 01/2012...
  • Page 317 “Backup Battery“ - “Master“ and “LANE A“ and “LANE B“ switches must be "OFF"! NOTICE WARNUNG Danger of damage to the fuel distribution sys- tem and ignition unit! 76-10-00 Effectivity: 912 i Series Edition 1/Rev. 1 Page 5 October 01/2013...
  • Page 318 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 319 - General visual inspection. See section 05-00- 00 and 12-20-00 in the corresponding Mainte- nance Manual Line for the 912 i Series engine type. 1. Coupler (LANE A1) 2. Coupler (LANE A2)
  • Page 320 - General visual inspection. See section 05-00- The ECU can only be replaced as a NOTE: 00 and 12-20-00 in the corresponding Mainte- complete spare part. nance Manual Line for the 912 i Series engine type. CONTROL UNIT - INSTALLATION Step Procedure...
  • Page 321 EXTRACTING ENGINE CONTROL UNIT (ECU) LOGS INTRODUCTION The intention of this procedural instruction is to guide users through a log-extraction process from an Engine Control Unit (ECU) with BRP 76-10-00 Effectivity: 912 i Series Edition 1/Rev. 1 Page 9 October 01/2013...
  • Page 322 Now the setup should be as shown in the ECU. Fig. 8. Fig. 8 09958 1. Computer 2. B.U.D.S. Aircraft Set 3. Y-cabel 4. Service Wiring Harness 5. ECU 6. Power Supply Effectivity: 912 i Series 76-10-00 Edition 1/Rev. 1 Page 10 October 01/2013...
  • Page 323 Change from “Diagnostic Mode“ Tab to “Maintenance Mode“ Tab. If the ECU at the time is supplied with NOTE: power, a restart is required. 09962 B.U.D.S. Aircraft “Preferences“ 76-10-00 Effectivity: 912 i Series Edition 1/Rev. 1 Page 11 October 01/2013...
  • Page 324 NOTICE: The User must have writing per- Click on “Extract Logs“. A settings window mission for this folder. named “ECU Log Extraction“ should open. Press “OK“ subsequently. The extraction process will start. Effectivity: 912 i Series 76-10-00 Edition 1/Rev. 1 Page 12 October 01/2013...
  • Page 325 Disconnect Y-cable and Service Wiring Harness connectors With the Windows Explorer navigate to the created Log-File. This file can now be copied and for example attached to an E- Mail. 76-10-00 Effectivity: 912 i Series Edition 1/Rev. 1 Page 13 October 01/2013...
  • Page 326 LANE A and LANE B are not conduct- ble, the length should not exceed ed separately, the B.U.D.S. Aircraft 2 meters. Set Sub-D DE9 connector can be linked to the maintenance interface directly. Effectivity: 912 i Series 76-10-00 Edition 1/Rev. 1 Page 14 October 01/2013...
  • Page 327 Change from “ Diagnostic Mode“ Tab to “Maintenance Mode“ Tab. If the ECU at the time is supplied with NOTE: power, a restart is required. 09962 B.U.D.S. Aircraft “Preferences“ 76-10-00 Effectivity: 912 i Series Edition 1/Rev. 1 Page 15 October 01/2013...
  • Page 328 4. LANE B Switch Step Procedure The connection state (bottom-right corner of B.U.D.S.) for both LANES should turn “RED“ to “ORANGE“ and finally to “GREEN“. See also Fig. Effectivity: 912 i Series 76-10-00 Edition 1/Rev. 1 Page 16 October 01/2013...
  • Page 329 Fig. 21 09965 B.U.D.S. Aircraft settings for Log-extraction NOTICE WARNUNG Extraction process could take several minutes depending on the number of logs. 09964 „B.U.D.S. Aircraft „Maintenance Mode“ : Logs 76-10-00 Effectivity: 912 i Series Edition 1/Rev. 1 Page 17 October 01/2013...
  • Page 330 Disconnect USB to CAN Converter With the Windows Explorer navigate to the created Log-File. This file can now be copied and for example attached to an E- Mail. Effectivity: 912 i Series 76-10-00 Edition 1/Rev. 1 Page 18 October 01/2013...
  • Page 331 Software versions as long as there is no additional information given by WARNUNG WARNING ROTAX in form of Service Bulletins. Before loading new ECU Software When detaching the ECU from the Aircraft make make sure that you have installed the sure that latest version B.U.D.S.
  • Page 332 LANE A1 and LANE B connectors of the ECU. Fig. 23 09958 1. Computer 2. B.U.D.S. Aircraft Set Level 3. Y-cable 4. Service Wiring Harness 5. ECU 6. Power Supply Effectivity: 912 i Series 76-10-00 Edition 1/Rev. 1 Page 20 October 01/2013...
  • Page 333 Change to “Maintenance Mode“ Tab. 09963 Fig. 25 B.U.D.S. Aircraft “Maintenance Mode“ Step Procedure Check the currently installed ECU Soft- wareversion and the set Engine type. 09961 B.U.D.S. Aircraft “Maintenance Mode“ 76-10-00 Effectivity: 912 i Series Edition 1/Rev. 1 Page 21 October 01/2013...
  • Page 334 ECU (see SB-912 i-002iS). If the Engine Type in the ECU deviates from the hardware configuaration of 09966 the engine, contact a ROTAX Distributor B.U.D.S. Aircraft “Maintenance Mode“ : Software Load immediately. Step Procedure Fig.
  • Page 335 Sensor Status and Device Status in All cable can be disconnected. following Fig. 29. If there are additional Errors/Events the ECU might be dam- aged and further investigation needs to be done. 76-10-00 Effectivity: 912 i Series Edition 1/Rev. 1 Page 23 October 01/2013...
  • Page 336 LANE A and LANE B are not conduct- ble, the length should not exceed ed separately, the B.U.D.S. Aircraft 2 meters. Satz Sub-D DE9 connector can be linked to the maintenance interface directly. Effectivity: 912 i Series 76-10-00 Edition 1/Rev. 1 Page 24 October 01/2013...
  • Page 337 Change to “Maintenance Mode“-Tab. Fig. 32 09963 B.U.D.S. Aircraft „Maintenance Mode“ Step Procedure Check the currently installed ECU Soft- wareversion and the set Engine Type. 09961 B.U.D.S. Aircraft „Maintenance Mode“ 76-10-00 Effectivity: 912 i Series Edition 1/Rev. 1 Page 25 October 01/2013...
  • Page 338 SB-912 i-002iS). If the set Engine Type set in the ECU deviates from the hardware configua- Do not disconnect or power down the ECU du- ration of the engine, contact a ROTAX Distribu- ring the Software flashing process. tor immediately.
  • Page 339 The Software flashing process itself is now complete. Turn the “Master“ Switch“, the “Battery Backup“-Switch and the “LANE A/B“ Switches back to “OFF“. Remove all wiring connections. 76-10-00 Effectivity: 912 i Series Edition 1/Rev. 1 Page 27 October 01/2013...
  • Page 340 BRP-Powertrain MAINTENANCE MANUAL NOTES 76-10-00 Effectivity: 912 i Series Edition 1/Rev. 1 Page 28 October 01/2013...
  • Page 341 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 342 BRP-Powertrain MAINTENANCE MANUAL 1. Fuse box assy. 2. Rectifier regulator B 3. Rectifier regulator A 4. Sealing insert 5. Fuses 76-10-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 30 July 01/2012...
  • Page 343 - General visual inspection. See section 05-00- 00 and 12-00-00 in the corresponding Mainte- nance Manual Line for the 912 i Series engine type. 1. Regulator B 2. Gasket screw connection...
  • Page 344 Fig. 39 1. Regulator A 2. Regulator B 1. Regulator plate 2. Regulator B 3. M4 lock nut 4. 4.3 washer 5. M6 lock nut 6. 6.4 washer Effectivity: 912 i Series 76-10-00 Edition 1/Rev. 1 Page 32 October 01/2013...
  • Page 345 7.5 A Selector switch B 7.5 A Selector switch A 10 A Fuel pump B 10 A Fuel pump A 10 A Ignition 3t 10 A Ignition 1b 76-10-00 Effectivity: 912 i Series Edition 1/Rev. 1 Page 33 October 01/2013...
  • Page 346 M4 lock nut and washer. 1. Regulator B 2. DEUTSCH connector Tightening torque 1.2 Nm (10.7 in.lb.) 3. 2x ground cable 4. Regulator ground cable Effectivity: 912 i Series 76-10-00 Edition 1/Rev. 1 Page 34 October 01/2013...
  • Page 347 1. Regulator plate 2. Regulator B 3. M4 lock nut 4. 4.3 washer Fig. 45 5. M6 lock nut 6. 6.4 washer 1. Regulator A 2. Regulator B 76-10-00 Effectivity: 912 i Series Edition 1/Rev. 1 Page 35 October 01/2013...
  • Page 348 FINISHING WORK - Attach all the necessary fastenings (e.g. cable ties, holders, clamps etc.) of the wiring harness. - Carry out an engine test run. See section 70- 00-00. Effectivity: 912 i Series 76-10-00 Edition 1/Rev. 1 Page 36 October 01/2013...
  • Page 349 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 350 (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. 0 Page 2 July 01/2012...
  • Page 351 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 352 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 353 23. HIC B Connector 24. HIC A Connector 25. 12/M6 cable clamp 26. DIN 128-A6-FST lock washer 27. M6x14 Allen screw 28. 203x7.6 cable tie 29. 142x3.2 cable tie Effectivity: 912 i Series 76-50-00 Edition 1/Rev. 0 Page 5 July 01/2012...
  • Page 354 - Carry out an engine test run. See section 12- 20-00 in the corresponding Maintenance SAFETY INFORMATION Manual Line for the 912 i Series engine type. - Disconnect the wiring harness from the WARNUNG WARNING aircraft frame.
  • Page 355 Fig. 2 1. Earthing cable 2. Controller LANE A 3. Controller connector A 1. Tab 2. Connection socket 76-50-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 7 July 01/2012...
  • Page 356 Loosen the two round connectors (labelled LANE A, LANE B) from fuse box. NOTE: Unscrew the connector cap nut anti-clockwise. 1. M5x12 Allen screws 2. LANE IN 3. LANE OUT Effectivity: 912 i Series 76-50-00 Edition 1/Rev. 0 Page 8 July 01/2012...
  • Page 357 Press in the lock so that the clamp can be rotated. Press the clamp down until it latches. Remove the coupler. 1. Connector (fuel pump 1) 2. Screwdriver 76-50-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 9 July 01/2012...
  • Page 358 Step Procedure Carefully pull EGT_1 and EGT_2 (cy- linder 1 and 2) out of the locking plate. Press the metal bracket and separate the connectors. Effectivity: 912 i Series 76-50-00 Edition 1/Rev. 0 Page 10 July 01/2012...
  • Page 359 Press the metal bracket and separate the connectors. Fig. 18 1. M5x16 Allen screw 2. 5.3 washer 3. Plug holder Step Procedure 1. EGT connector Unplug the connection to the double igni- tion coils. 76-50-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 11 July 01/2012...
  • Page 360 Procedure Loosen the 2 M5 x12 Allen screws from 1. M5x12 Allen screw 2. 5.3 washer cover of the fuel rail. 3. Heat shield Lift off the cover. Effectivity: 912 i Series 76-50-00 Edition 1/Rev. 0 Page 12 July 01/2012...
  • Page 361 NOTE: Let the wire clip snap back in af- ter the connector has been dis- connected so that it does not get lost. 76-50-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 13 July 01/2012...
  • Page 362 Unplug the temperature sensor and pres- sure sensor: Lift the latches + pull out the connectors. Fig. 26 1. CPS_1 LANE A 2. CPS_2 LANE B 3. KNOCK knock sensor 1. Temperature sensor Effectivity: 912 i Series 76-50-00 Edition 1/Rev. 0 Page 14 July 01/2012...
  • Page 363 Press the metal bracket and separate the Fig. 29 connectors. Fig. 31 1. Pressure sensors 2. Temperature sensor 3. Cable ties 1. Temperature sensor Step Procedure Remove the cable ties on the airbox. 76-50-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 15 July 01/2012...
  • Page 364 Any modification e.g. to the wiring harness can lead to incorrect inputs or operating faults. - General visual inspection. See section 05-00- 00 and 12-20-00 in the corresponding Main- tenance Manual Line for the 912 i Series engine type. Effectivity: 912 i Series 76-50-00 Edition 1/Rev.
  • Page 365 4. Engine ate protective measures. Before connecting a connector, remove NOTE: the protective covering which may be at- tached both to the connector and to the connection socket. 76-50-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 17 July 01/2012...
  • Page 366 Pos. Part no. of connector set Corresponding tool 881290 Crimping pliers TYCO 539 635-1 Jaws TYCO 539 737-2 881292 Disassembly tool TYCO 1-1579007-6 881296 881298 881300 76-50-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 18 July 01/2012...
  • Page 367 See section 76-50-00 Removal. THROTTLE POTENTIOMETER - CONNEC- TION 1. Temperature sensor CTS 2. INJ_4 The sensors are connected and disconnected in the same way. See section 76-50-00 Removal. 76-50-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 19 July 01/2012...
  • Page 368 Double ignition coils are labelled + and -! Step Procedure Step Procedure Plug in the ignition coil connector and Plug in the connection to the double igni- EGT connector. tion coils. Effectivity: 912 i Series 76-50-00 Edition 1/Rev. 0 Page 20 July 01/2012...
  • Page 369 Tightening torque 10 Nm (88.48 in. lb.). Fig. 40 1. Plug holder 2. 203x7.6 mm cable tie 1. M6x14 Allen screw 2. 6.4 washer 3. 142x3.2 mm cable tie 3. 12/M6 cable clamp 76-50-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 21 July 01/2012...
  • Page 370 - Check the grounding for good contact and cleanliness. - Carry out an engine test run. See section 12- 20-00 in the corresponding Line Maintenance Manual for the 912 i Series engine type. Effectivity: 912 i Series 76-50-00 Edition 1/Rev. 0...
  • Page 371 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 372 Page 29 N. Double ignition coil - installation Page 29 O. Fuel pump - installation Page 29 P. Caution lamp - installation Page 29 10. Finishing work Page 29 76-70-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 2 July 01/2012...
  • Page 373 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 Edition 1/Rev. 0 Page 3 July 01/2012...
  • Page 374 5. Throttle potentiometer (TPS) 6. Temperature sensor 7. Pressure sensor 8. Temperature sensor (CTS and OTS) (MAPS 1 + 2) (MAPS 1 + 2) 9. Pressure sensor (OPS) 76-70-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 4 July 01/2012...
  • Page 375 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 376 The temperature sensors measure the tempera- crankshaft. ture of the exhaust gas and are used to regulate the injection quantity. 1 Temperature sensor – cooling system Wiring harness designation: CTS Effectivity: 912 i Series 76-70-00 Edition 1/Rev. 0 Page 6 July 01/2012...
  • Page 377 NOTE: whole unit. - General visual inspection. See relevant Main- WARNUNG WARNING tenance Manual Line for the 912 i Series engine type. Danger of injury when removing hose connec- tions, sensors and actuators! - Use the BUDS diagnostic unit for trouble- Risk of fire due to flammable substances (e.g.
  • Page 378 Pull the respective connector of the wiring harness out of the corresponding pres- sure sensor (MAPS_1/MAPS_2). See also section 76-50-00 Wiring harness (main strand). Lift the latch and pull off. Effectivity: 912 i Series 76-70-00 Edition 1/Rev. 0 Page 8 July 01/2012...
  • Page 379 Push in the tab on the top of the connector and at the same time pull the connector out of the connection socket. Follow the aircraft manufacturer's instruc- tions for disassembly. 1. Temperature sensor Cable ties 76-70-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 9 July 01/2012...
  • Page 380 1. Temperature sensor 2. Washer Step Procedure Use a size 17 open-ended spanner (or similar tool) to detach the temperature sensor from the exhaust pipe. Effectivity: 912 i Series 76-70-00 Edition 1/Rev. 0 Page 10 July 01/2012...
  • Page 381 - Remove the fuel line assy. See also section 73-10-00 Fuel system. - Unplug EGT 1/3. See also section 76-50-00 1. Temperature sensor 2. Cable ties Wiring harness. 76-70-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 11 July 01/2012...
  • Page 382 Loosen the M8x30 hex. screw. Remove the knock sensor. Fig. 15 1. Connector 2. Support plate Step Procedure Cut open the cable ties. 1. Knock sensor 2. Hex. screw Effectivity: 912 i Series 76-70-00 Edition 1/Rev. 0 Page 12 July 01/2012...
  • Page 383 Remove crankshaft position sensor assy. Close the bore with the appropriate pro- tective covering. NOTICE WARNUNG Ensure that the O-ring is positioned on the crankshaft position sensor assy. 76-70-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 13 July 01/2012...
  • Page 384 See also section 74-20-00 Distribution. FUEL PUMP - REMOVAL To do this, see section 73-10-00 Fuel pump and distribution. CAUTION LAMP - REMOVAL See documentation of aircraft manufacturer. Effectivity: 912 i Series 76-70-00 Edition 1/Rev. 0 Page 14 July 01/2012...
  • Page 385 Fig. 19 the MAINTENANCE TOOL and then deleted. Functional test The function of the sensors and actuators must be checked with the ECU activated. 06342 R Ohmmeter V Consumer 76-70-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 15 July 01/2012...
  • Page 386 Fig. 21 Fig. 20 Voltage supply 06344 06342 V Parallel-connected voltmeter R Consumer R Ohmmeter T Temperature sensor Effectivity: 912 i Series 76-70-00 Edition 1/Rev. 0 Page 16 July 01/2012...
  • Page 387 The circuit must be disconnected in order to measure the amperage. The measure- ment unit (ammeter) is connected in be- tween. Fig. 22 Voltage supply 06343 A Series-connected ammeter R Consumer 76-70-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 17 July 01/2012...
  • Page 388 5 V ± 0.5 0.5 ..4.5 V corresponds to 0 to 10 bar GROUND Measurement Current Pressure (bar/psi) [in V] 10 bar / 145 psi 4.5 V 06353 06345 76-70-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 18 July 01/2012...
  • Page 389 9395 +/- 7 % 0/32 °F 5895 +/- 7 % 20 °C/38 °F 2499 +/-6 % 80 °C/176 °F 323 +/-3 % 100 °C/212 °F 187 +/- 2 % 06354 06345 Effectivity: 912 i Series 76-70-00 Edition 1/Rev. 0 Page 19 July 01/2012...
  • Page 390 - Check the O-ring on the crankshaft position sensor - Check the thread - Check the crankshaft position sensor surface - Check the crankshaft position sensor bore Effectivity: 912 i Series 76-70-00 Edition 1/Rev. 0 Page 20 July 01/2012...
  • Page 391 Value [in V] Remarks Supply Voltage + 5 V Earth offset Signal 0.25 to 4.7 V Measurement Voltage Position [in V] Closed 0.25 V Max. opened 4.7 V 06355 06356 76-70-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 21 July 01/2012...
  • Page 392 Risk of damage to engine management system components! There is a risk of a permanent by- pass (fuel pressure surge). Voltage and resistance test Ω - The internal resistance is about 12 Effectivity: 912 i Series 76-70-00 Edition 1/Rev. 0 Page 22 July 01/2012...
  • Page 393 06358 FUEL PUMP - INSPECTION To do this, see section 73-10-00 Fuel pump and distribution. CAUTION LAMP - INSPECTION See also section 77-40-01 Caution lamps. 76-70-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 23 July 01/2012...
  • Page 394 Procedure Plug the respective wiring harness con- nector into the corresponding pressure sensor. See section 76-50-00. Attach cable ties (strain relief). 1. Pressure sensors (MAPS_1/MAPS_2) 2. Cable ties Effectivity: 912 i Series 76-70-00 Edition 1/Rev. 0 Page 24 July 01/2012...
  • Page 395 See section 76-50-00. Attach cable ties (strain relief). Fig. 28 1. Temperature sensor (CTS) 1. Temperature sensor (MATS) 2. Cable ties 76-70-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 25 July 01/2012...
  • Page 396 Clean the thread of the temperature sen- sor. Lubricate thread of temperature sensor with LOCTITE ANTI SEIZE. Fig. 31 1. Temperature sensor (OTS) Step Procedure Attach cable ties. 1. Temperature sensor 2. Inlet pipe Effectivity: 912 i Series 76-70-00 Edition 1/Rev. 0 Page 26 July 01/2012...
  • Page 397 Tighten the knock sensor. 1. Connector (KNOCK) 2. Locking plate Tightening torque 20 Nm (176.96 in.lb.). Step Procedure Attach the cables of the knock sensor with 2 cable ties. 76-70-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 27 July 01/2012...
  • Page 398 Push the cable clamp onto the cable. NOTICE WARNUNG Arrange the cable so that it does not rest against the engine suspension frame or other compo- nents. 1. Connector (CPS) 2. Locking plate Effectivity: 912 i Series 76-70-00 Edition 1/Rev. 0 Page 28 July 01/2012...
  • Page 399 To do this, see section 73-10-00 Fuel pump and distribution. FUEL PUMP - INSTALLATION To do this, see section 73-10-00 Fuel pump and distribution. CAUTION LAMP - INSTALLATION See documentation of aircraft manufacturer. 76-70-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 29 July 01/2012...
  • Page 400 BRP-Powertrain MAINTENANCE MANUAL NOTES 76-70-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 30 July 01/2012...
  • Page 401 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 402 BRP-Powertrain MAINTENANCE MANUAL Exhaust system 78-00-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 2 July 01/2012...
  • Page 403 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 404 BRP-Powertrain MAINTENANCE MANUAL NOTES 78-00-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 4 July 01/2012...
  • Page 405 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 406 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 407 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 408 BRP-Powertrain MAINTENANCE MANUAL Exhaust 78-10-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 4 July 01/2012...
  • Page 409 MAINTENANCE As well as the maintenance and special checks, see the relevant Maintenance Manual Line for the respective 912 i Series engine type. REMOVAL EXHAUST ASSY. - REMOVAL 1. Exhaust flange 2.
  • Page 410 Procedure Check the conical seal in the cylinder head and on the exhaust pipe for defor- mation. Fig. 3 1. Conical seal 2. Exhaust flange 3. Exhaust pipe Effectivity: 912 i Series 78-10-00 Edition 1/Rev. 0 Page 6 July 01/2012...
  • Page 411 Fig. 5 1. M8 hex. nut 2. Exhaust flange 3. Exhaust pipe 4. Cylinder head EXHAUST ASSY. - INSTALLATION NOTICE WARNUNG Follow the aircraft manufacturer's instructions for installation. 78-10-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 7 July 01/2012...
  • Page 412 BRP-Powertrain MAINTENANCE MANUAL NOTES 78-10-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 8 July 01/2012...
  • Page 413 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 414 A. Pressure sensor (OIL) - installation Page 25 34. Component repair Page 26 A. Thread Page 26 (1) Magnetic drain plug Page 26 (2) Drain plug Page 26 B. Flat areas Page 26 79-00-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 2 July 01/2012...
  • Page 415 BRP-Powertrain MAINTENANCE MANUAL Effectivity: 912 i Series 79-00-00 Edition 1/Rev. 0 Page 3 July 01/2012...
  • Page 416 BRP-Powertrain MAINTENANCE MANUAL NOTES 79-00-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 4 July 01/2012...
  • Page 417 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. Effectivity: 912 i Series 79-00-00 Edition 1/Rev. 0 Page 5 July 01/2012...
  • Page 418 BRP-Powertrain MAINTENANCE MANUAL Lubrication system 79-00-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 6 July 01/2012...
  • Page 419 The oil pump is driven by the camshaft. see the relevant Maintenance Manual Line for PURGING OF LUBRICATION SYSTEM the respective 912 i Series engine type. The oil circuit is purged via the air bleed line Whenever the lubrication system is re- NOTE: attached to the oil tank.
  • Page 420 3. Regulator pressure oil line Step Procedure Unscrew the oil filter with oil filter wrench part no. 877620. Fig. 2 1. Oil filter 2. Special tool Effectivity: 912 i Series 79-00-00 Edition 1/Rev. 0 Page 8 July 01/2012...
  • Page 421 Fig. 5 Fig. 7 1. Oil pump cover 2. Soft-faced hammer 1. Oil pump shaft 2. Feather key 79-00-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 9 July 01/2012...
  • Page 422 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. 0 Page 10 July 01/2012...
  • Page 423 Check the sealing faces of the oil pump housing and pump cover for striations, where necessary pull them off on a pull- out plate. 1. Rotor 2. Rotary piston 79-00-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 11 July 01/2012...
  • Page 424 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. 0 Page 12 July 01/2012...
  • Page 425 4.075 mm 4.150 mm current in shaft 0.157 in. 0.160 in. 0.163 in. replaced Pressure spring OP03 65.6 mm (2.5827 in.) 62.6 mm current length (2.4646 in.) replaced Effectivity: 912 i Series 79-00-00 Edition 1/Rev. 0 Page 13 July 01/2012...
  • Page 426 4. Soft-faced hammer the oil pump shaft while turning slightly. NOTICE WARNUNG The oil pump shaft must not be pulled out again, otherwise the oil seal is unusable. Effectivity: 912 i Series 79-00-00 Edition 1/Rev. 0 Page 14 July 01/2012...
  • Page 427 Hold the oil pump shaft when putting the oil pump cover on it. Otherwise the oil pump shaft is pushed out by the air cushion. 1. Rotor (inner rotor) 2. Rotary piston (outer rotor) 3. Mark 79-00-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 15 July 01/2012...
  • Page 428 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. 0 Page 16 July 01/2012...
  • Page 429 3. O-rings Step Procedure Apply LOCTITE 5910 to the support area on the crankcase. 1. M6x50 Allen screws 2. 6.4 washers 3. M22x1.5 plug screw 4. Oil filter 79-00-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 17 July 01/2012...
  • Page 430 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.
  • Page 431 Remove surrounding assemblies and detach oil lines. ENVIRONMENT NOTE Ensure that no oil gets into the waste water sys- tem or the ground – risk of contaminating drin- king water! 79-00-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 19 July 01/2012...
  • Page 432 Step Procedure General visual inspection. See rele- 1. Oil tank 2. Oil tank cover assy. vant Maintenance Manual Line for the 912 i Series engine type. 3. O-Ring 4. Profile clamp Step Procedure Remove the baffle insert and partition from the oil tank.
  • Page 433 - Fill with fresh oil. - Remove surrounding assemblies and detach See relevant Maintenance Manual Line for oil lines. the 912 i Series. The assemblies and lines are only to be NOTE: removed if necessary and only as far as - Bleed the oil system.
  • Page 434 Preparation - Clean all parts carefully. See also section 05- 00-00 Procedures - General visual inspection. See relevant Main- tenance Manual Line for the 912 i Series engine type. Step Procedure Clean the cooling fins of the oil cooler and straighten them out if necessary.
  • Page 435 See also sec- - General visual inspection. See relevant Main- tion 61-20-00 Governor. tenance Manual Line for the 912 i Series Loosen the banjo bolt on the oil pump engine type. housing and remove it along with the gas- ket rings.
  • Page 436 If it rises above this, certification for replacement. - the lubrication system (See relevant Main- Only use suitable screw hose clamps or tenance Manual Line for the 912 i Series crimp connections to fasten the lines. engine type) OIL LINE (STEEL LINE) INSTALLATION...
  • Page 437 WARNUNG The pressure range of the display device must match the pressure range of the pressure sen- sor. Otherwise the oil pressure will not be dis- played correctly. 79-00-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 25 July 01/2012...
  • Page 438 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 439 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 440 BRP-Powertrain MAINTENANCE MANUAL 80-00-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 2 July 01/2012...
  • Page 441 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 442 BRP-Powertrain MAINTENANCE MANUAL Electric starter 80-00-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 4 July 01/2012...
  • Page 443 - Ignition, main and LANE selector switches must be "OFF"! MAINTENANCE As well as the maintenance and special checks, see the relevant Maintenance Manual Line for the respective 912 i Series engine type. REMOVAL Preparation - Switch the ignition key OFF 1. Electric starter 2.
  • Page 444 INSPECTION ELECTRIC STARTER DISASSEMBLY, INS- PECTION, ASSEMBLY NOTICE WARNUNG Only allowed for HD starters! Fig. 3 1. Electric starter 2. Rotor 3. O-Ring Effectivity: 912 i Series 80-00-00 Edition 1/Rev. 0 Page 6 July 01/2012...
  • Page 445 Tightening torque 6 Nm (53.09 in. lb.). board battery. Connect the positive pole on the electric - Carry out an engine test run. See relevant starter. Maintenance Manual Line for the 912 i Series engine type. Fig. 4 1. Electric starter 2. Ignition housing 3.
  • Page 446 BRP-Powertrain MAINTENANCE MANUAL NOTES 80-00-00 Effectivity: 912 i Series Edition 1/Rev. 0 Page 8 July 01/2012...
  • Page 448 AIRCRAFT ENGINES www.cps-parts.com 800-247-9653...

This manual is also suitable for:

912 is912 isc

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