BRP ROTAX 912 i Series Maintenance Manual
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BRP ROTAX 912 i Series Maintenance Manual

BRP ROTAX 912 i Series Maintenance Manual

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MAINTENANCE
MANUAL
FOR ROTAX® ENGINE TYPE 912 i SERIES
HEAVY MAINTENANCE | REF. NO.: MMH-912 i | PART NO.: 898752

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  • Page 1 MAINTENANCE MANUAL FOR ROTAX® ENGINE TYPE 912 i SERIES HEAVY MAINTENANCE | REF. NO.: MMH-912 i | PART NO.: 898752...
  • Page 2 WARNING Before starting any maintenance work, please read the ROTAX® is a trade mark of BRP-Rotax GmbH & Co KG. In the Maintenance Manual completely as it contains important following document the short form of BRP-Rotax GmbH & safety relevant information. Failure to do so may result Co KG = BRP-Rotax is used.
  • Page 3 BRP-Rotax MAINTENANCE MANUAL HEAVY Table of Content Chapter INTRO – GENERAL NOTE Chapter LEP – LIST OF EFFECTIVE PAGES Chapter TOA – TABLE OF AMENDMENTS Chapter 00–00–00 – GENERAL NOTE Chapter 24–20–00 – Internal Generator Chapter 24–30–00 – External Alternator Chapter 37–10–00 –...
  • Page 4 BRP-Rotax MAINTENANCE MANUAL HEAVY INTENTIONALLY LEFT BLANK Page 2 Effectivity: 912 i Series Edition 2 / June 01 2024 Rev. 0...
  • Page 5 ROTAX® Authorized Aircraft Engines Distributors or their independent Service Centers. BRP-Rotax wishes you much pleasure and satisfaction flying your aircraft powered by this ROTAX®-aircraft engine. The structure of the Manual follows whenever it is possible the structure of the ATA (Air Transport Association) standards.
  • Page 6 BRP-Rotax MAINTENANCE MANUAL HEAVY INTENTIONALLY LEFT BLANK Page 2 Effectivity: 912 i Series Edition 2 / June 01 2024 Rev. 0...

  • Page 7: List Of Effective Pages

    BRP-Rotax MAINTENANCE MANUAL HEAVY Chapter: LEP LIST OF EFFECTIVE PAGES Each new revision to the Maintenance Manual will have a new List of Effective Pages. Chapter Page Date Chapter Page Date Title page June 01 2024 June 01 2024 INTRO...
  • Page 8 BRP-Rotax MAINTENANCE MANUAL HEAVY Chapter Page Date Chapter Page Date June 01 2024 June 01 2024 June 01 2024 June 01 2024 June 01 2024 June 01 2024 June 01 2024 June 01 2024 June 01 2024 June 01 2024...
  • Page 9 BRP-Rotax MAINTENANCE MANUAL HEAVY Chapter Page Date Chapter Page Date June 01 2024 June 01 2024 June 01 2024 June 01 2024 June 01 2024 72-00-00 June 01 2024 June 01 2024 June 01 2024 June 01 2024 June 01 2024...
  • Page 10 BRP-Rotax MAINTENANCE MANUAL HEAVY Chapter Page Date Chapter Page Date June 01 2024 June 01 2024 June 01 2024 June 01 2024 June 01 2024 June 01 2024 June 01 2024 June 01 2024 June 01 2024 June 01 2024...
  • Page 11 BRP-Rotax MAINTENANCE MANUAL HEAVY Chapter Page Date Chapter Page Date June 01 2024 June 01 2024 June 01 2024 June 01 2024 June 01 2024 June 01 2024 June 01 2024 June 01 2024 June 01 2024 June 01 2024...
  • Page 12 BRP-Rotax MAINTENANCE MANUAL HEAVY Chapter Page Date Chapter Page Date June 01 2024 June 01 2024 June 01 2024 June 01 2024 June 01 2024 June 01 2024 74-20-00 June 01 2024 June 01 2024 June 01 2024 June 01 2024...
  • Page 13 BRP-Rotax MAINTENANCE MANUAL HEAVY Chapter Page Date Chapter Page Date June 01 2024 June 01 2024 June 01 2024 June 01 2024 June 01 2024 June 01 2024 June 01 2024 June 01 2024 June 01 2024 June 01 2024...
  • Page 14 BRP-Rotax MAINTENANCE MANUAL HEAVY Chapter Page Date Chapter Page Date June 01 2024 June 01 2024 June 01 2024 June 01 2024 June 01 2024 79-00-00 June 01 2024 June 01 2024 June 01 2024 June 01 2024 June 01 2024...
  • Page 15 BRP-Rotax MAINTENANCE MANUAL HEAVY Chapter Page Date June 01 2024 Index Rear page Effectivity: 912 i Series Rev. 0 Page 9 Edition 2 / June 01 2024...
  • Page 16 BRP-Rotax MAINTENANCE MANUAL HEAVY INTENTIONALLY LEFT BLANK Page 10 Effectivity: 912 i Series Edition 2 / June 01 2024 Rev. 0...
  • Page 17 BRP-Rotax MAINTENANCE MANUAL HEAVY Chapter: TOA TABLE OF AMENDMENTS Approval* The technical content of this document is approved under the authority of the DOA ref. EASA.21.J.048. July 01 2018 Edition 1/Rev. 3 Obsolete with Edition 2/Rev. 0, which is a complete new edition.
  • Page 18 BRP-Rotax MAINTENANCE MANUAL HEAVY Cur- Chapter Page Date of change Remark Date of Date of Signature rent approval inclusion approval from authori- ties 76-00-00 June 01 2024 DOA* 76-10-00 June 01 2024 DOA* 76-50-00 June 01 2024 DOA* 76-70-00 June 01 2024...
  • Page 19 BRP-Rotax MAINTENANCE MANUAL HEAVY Summary of amendments Summary of the relevant amendments in this context, but without any claim to completeness. Cur- Chapter Page Date of change Comment rent June 01 2024 New edition of book: new chapters, topics and figures Effectivity: 912 i Series Rev.
  • Page 20 BRP-Rotax MAINTENANCE MANUAL HEAVY INTENTIONALLY LEFT BLANK Page 4 Effectivity: 912 i Series Edition 2 / June 01 2024 Rev. 0...

  • Page 21: Table Of Contents

    BRP-Rotax MAINTENANCE MANUAL HEAVY Chapter: 00–00–00 GENERAL NOTE TOPICS IN THIS CHAPTER General..............................2 Type description............................3 Abbreviations and terms (depending on respective engine type)............4 Wiring color codes ..........................9 Conversion table ..........................10 Safety notice ............................11 Safety information ..........................12 Instruction............................14 Maintenance Concept..........................15 Technical documentation........................16...

  • Page 22: General

    BRP-Rotax MAINTENANCE MANUAL HEAVY GENERAL Purpose The purpose of this Maintenance Manual is to acquaint maintenance service staff (iRMT) approved by the local aviation authorities with some basic maintenance and safety infor- mation for service work.. Documentation For more detailed information related to aircraft and aircraft/engine installation, mainte- nance, safety or flight operation, consult the documentation provided by the aircraft manu- facturer and/or its dealer.

  • Page 23: Type Description

    2 for configuration 3 NOTE Conversion of the version 2 to version 3 and vice versa may be accomplished by BRP-Rotax Authorized Distributors or their Service Center. Effectivity: 912 i Series 00–00–00 Rev. 0 Page 3 Edition 2 / June 01 2024...

  • Page 24: Abbreviations And Terms (Depending On Respective Engine Type)

    BRP-Rotax MAINTENANCE MANUAL HEAVY ABBREVIATIONS AND TERMS (DEPENDING ON RESPECTIVE ENGINE TYPE) Abbreviations Description Reference to another section center of gravity The drop symbol indicates use of sealing agents, adhesives or lubricants (only in the Maintenance Manual Heavy) °C Degrees Celsius (Centigrade) °F...
  • Page 25 BRP-Rotax MAINTENANCE MANUAL HEAVY Abbreviations Description clockwise counter-clockwise CGSB Canadian General Standards Board DCDI Dual Capacitor Discharge Ignition direct current Design Organisation Approval Department of Transport EASA European Aviation Safety Agency Installation Manual Engine Control Unit Exhaust Gas Temperature Introduction...
  • Page 26 BRP-Rotax MAINTENANCE MANUAL HEAVY Abbreviations Description Illustrated Parts Catalog inch per second iRMT independent ROTAX Maintenance Technician International Standard Atmosphere Kilograms KNOCK Knock sensor Lane A System A of Engine Management System Lane B System B of Engine Management System...
  • Page 27 Description PTFE Polytetrafluoroethylene (Teflon) Power Take Off Rev. Revision ROTAX® is a trademark of BRP-Rotax GmbH & Co KG Research Octane Number RON 424 ROTAX® Standard 424 s.v. still valid (only Illustrated Parts Catalog) Serial Number Society of Automotive Engineers...
  • Page 28 BRP-Rotax MAINTENANCE MANUAL HEAVY Abbreviations Description Connector on Engine Management System wiring harness which serves as an inter- face for power supply XXXX shows the component serial number 00–00–00 Effectivity: 912 i Series Rev. 0 Page 8 Edition 2 / June 01 2024...

  • Page 29: Wiring Color Codes

    BRP-Rotax MAINTENANCE MANUAL HEAVY WIRING COLOR CODES Figure 1.2 Effectivity: 912 i Series 00–00–00 Rev. 0 Page 9 Edition 2 / June 01 2024...

  • Page 30: Conversion Table

    BRP-Rotax MAINTENANCE MANUAL HEAVY CONVERSION TABLE Units of length: Units of power: 1 mm = 0.03937 in 1 kW = 1.341 hp 1 in = 25.4 mm 1 hp = 0.7457 kW 1 ft = 12 in 1 kW = 1.3596 PS = 0.3048 m...

  • Page 31: Safety Notice

    The information and descriptions of components and systems contained in this Manual are correct at the time of publication. BRP-Rotax maintains a policy of continuous im- provement of its products without imposing upon itself any obligation to retrofit products previously manufactured.

  • Page 32: Safety Information

    • Due to the varying designs, equipment and types of aircraft, BRP-Rotax grants no war- ranty on the suitability of its engines use on any particular aircraft. Further, BRP-Rotax...
  • Page 33 BRP-Rotax MAINTENANCE MANUAL HEAVY Engine operation • The engine must always be operated according to the content of the latest Operators Manual (OM) • To eliminate the risk of injury or damage, ensure any loose equipment or tools are prop- erly secured before starting the engine •...

  • Page 34: Instruction

    Accessories This engine must only be operated with accessories supplied, recommended and re- leased by BRP-Rotax. Modifications are only allowed after consent of the engine manufacturer. Spare parts See Illustrated Parts Catalog (IPC), latest issue for the respective engine type.

  • Page 35: Maintenance Concept

    BRP-Rotax MAINTENANCE MANUAL HEAVY See latest Operators Manual (OM) and Service Instruction SI-912 i-001 “Selection of suitable operating fluids“, current issue. MAINTENANCE CONCEPT General note The maintenance functions detailed in this Manual are divided into two categories: • Maintenance I (Line Maintenance) •...

  • Page 36: Technical Documentation

    BRP-Rotax MAINTENANCE MANUAL HEAVY TECHNICAL DOCUMENTATION These documents form the instructions ensuring continued airworthiness of ROTAX® air- craft engines. The information contained herein is based on data and experience that are considered ap- plicable for authorized mechanics (iRMT, see MML, Chapter 05–00–00 section “Author- ized Personnel”) under normal conditions for engine removal and installation.
  • Page 37 BRP-Rotax MAINTENANCE MANUAL HEAVY NOTICE Pay attention to references to other documentation, found in various parts of this Manual. If not stated otherwise, any reference to a document refers to the latest edition issued by BRP-Rotax. This symbol informs you of additional references (data sheets, Manuals, etc.) associated with the given subject.

  • Page 38: Use For Intended Purpose

    NOTE These engines are technically equivalent to certified engines and have been man- ufactured by BRP-Rotax using the same quality assurance system. Engine stoppage In using the engine the operator assumes all risk of use and acknowledges that he/she knows this engine is subject to sudden stoppage.

  • Page 39: Inspection Of Parts And Report Of Findings

    BRP-Rotax MAINTENANCE MANUAL HEAVY INSPECTION OF PARTS AND REPORT OF FINDINGS General note Measure all parts listed in the dimension sheets. These are attached directly after each section. All measurements must be entered in the corresponding dimension sheets as shown.
  • Page 40 BRP-Rotax MAINTENANCE MANUAL HEAVY • The respective actual value must be entered in the corresponding box (6) in [mm] or [inches] • The actual value for any part which has been replaced must be entered in the corre- sponding field (7) in [mm] or [inches] List of abbreviations The following table shows the abbreviations used for the control points.

  • Page 41: Classification Of Parts For Maintenance/Repair

    BRP-Rotax MAINTENANCE MANUAL HEAVY CLASSIFICATION OF PARTS FOR MAINTENANCE/REPAIR General note As for an overhaul, parts for maintenance/repair must be classified. They are classified ei- ther as “parts usable“ (“On-Condition“) or as “parts to be replaced“ (“100 % Parts“). Criteria The classification is made on the basis of following criteria: •...
  • Page 42 BRP-Rotax MAINTENANCE MANUAL HEAVY TSN [h] max. permissible wear Time Since New for repair [%] from TBO 2000 h – 912 i Series 1201 1300 1301 1400 1401 1500 1501 1600 1601 1700 1701 1800 1801 1900 1901 2000 Determination of actual wear [%] •...
  • Page 43 BRP-Rotax MAINTENANCE MANUAL HEAVY Classification of “On-Condition“ parts at maintenance/repair: Actual wear [%] is greater than or equal to the Parts must be replaced max. permissible wear [%] calculated from the table Actual wear [%] is smaller than the max. permis-...

  • Page 44: Maintenance

    BRP-Rotax MAINTENANCE MANUAL HEAVY MAINTENANCE General note Beyond the maintenance and special checks (see therefore Line Maintenance Manual), as well as the system descriptions hitherto, the following sections describe the mainte- nance procedures for affected engine type. The description is subdivided into subsections and descriptions of the function of the various systems.

  • Page 45: Fastener Information

    BRP-Rotax MAINTENANCE MANUAL HEAVY NOTE Always torque screws, bolts and/or nuts using a crisscross pattern when multiple fasteners are used to secure a part. Some parts must be torqued according to a specific sequence and torque pattern as detailed in the installation procedure.

  • Page 46: Loctite Application Procedure

    BRP-Rotax MAINTENANCE MANUAL HEAVY LOCTITE APPLICATION PROCEDURE The following describes common procedures used when working with LOCTITE products. NOTE Always use proper strength LOCTITE product as recommend in this Manual. Observe the instructions of the manufacturer! Thread locker application Thread locker application for uncovered holes (Bolts and nuts).
  • Page 47 BRP-Rotax MAINTENANCE MANUAL HEAVY Thread locker for blind holes Thread locker application for blind holes. Figure 1.7: Application for blind holes On fastener threads On threads and at the bottom of hole Step Procedure Clean threads (bolt and nut) with solvent.
  • Page 48 BRP-Rotax MAINTENANCE MANUAL HEAVY Thread locker for stud installation Thread locker application for stud installation in blind holes. Figure 1.8: Application for stud installation in blind holes On stud threads On threads and in the hole On retaining nut threads...
  • Page 49 BRP-Rotax MAINTENANCE MANUAL HEAVY Thread locker for pre-assembled parts Thread locker application for pre-assembled parts. B00003 Figure 1.9: Application for pre-assembled parts Apply here Do not apply Step Procedure Clean bolts and nuts with solvent. Assemble components. Tighten nuts. Apply a few drops of proper strength LOCTITE on bolt/nut contact surfaces.
  • Page 50 BRP-Rotax MAINTENANCE MANUAL HEAVY Thread locker for an adjustment screw Thread locker application for an adjustment screw. B00004 Figure 1.10: Application for an adjustment screw Apply here Plunger Step Procedure Adjust screw to proper setting. Apply a few drops of proper strength LOCTITE thread locker on screw/body contact surfaces.

  • Page 51: Consumable Materials

    BRP-Rotax MAINTENANCE MANUAL HEAVY CONSUMABLE MATERIALS NOTICE Use only the specified or technically equivalent materials for all maintenance work. NOTICE When handling chemicals, comply with all the customary regulations and specifi- cations of the producer, including the expiry date and instructions of use.
  • Page 52 BRP-Rotax MAINTENANCE MANUAL HEAVY Part no. Description, application Qty. 897330 LITHIUM-BASE GREASE 250 g Electrical isolating n.a. Engine oil For easier assembly of components or for first lubrica- tion before first engine start 899791 LOCTITE 5910 50 ml Flange sealant provides flexibility and adhesion...
  • Page 53 BRP-Rotax MAINTENANCE MANUAL HEAVY Additional materials NOTICE All metal and synthetic parts should be cleaned with suitable cleaning agents. Before using new and unknown cleaning agents, check their compatibility with the materials they are being used on. Part no. Description, application Qty.
  • Page 54 BRP-Rotax MAINTENANCE MANUAL HEAVY Part no. Description, application Qty. n.a. Valve lapping paste This paste, produced by various manufacturers, is a fine granulate lapping paste for manual lapping of valve seats and valves. The paste is usually available in 3 dif- ferent granulate sizes.

  • Page 55: Tools

    BRP-Rotax MAINTENANCE MANUAL HEAVY TOOLS Auxiliary tools • Differential compression tester or 2 pressure gauges with calibrated orifice, adapter for dial gauge in spark plug thread • Valve spring mounting pliers • Step punch for valve guide • Adjustable reamer 6.5 to 7.5 mm (0.256 to 0.295 in.) •...
  • Page 56 BRP-Rotax MAINTENANCE MANUAL HEAVY Disassembly device • Disassembly device for propeller gearbox Fig. shows one possible tensioning device for the disassembly of the propeller gearbox. The dimensions given are only intended for easier orientation and are not binding. Figure 1.12: Disassembly device 00–00–00...
  • Page 57 BRP-Rotax MAINTENANCE MANUAL HEAVY Measuring tools Calliper rule, dial gauge indicator, micrometer, inner micrometer, inner fine measuring de- vice, feeler gauge, spring scale up to 50 kp (500 N) (112.5 lbf). Accepted accuracy for different measuring tools: Pressure: +/- 5% Distances: •...
  • Page 58 BRP-Rotax MAINTENANCE MANUAL HEAVY INTENTIONALLY LEFT BLANK Page 38 Effectivity: 912 i Series Edition 2 / June 01 2024 Rev. 0...
  • Page 59 BRP-Rotax MAINTENANCE MANUAL HEAVY Chapter: 24–20–00 INTERNAL GENERATOR TOPICS IN THIS CHAPTER Special Tools ............................3 Service Products .............................4 System description ..........................6 EMS Power Supply..........................6 Drive ..............................6 Safety instruction...........................6 Maintenance ............................6 General information – removal........................6 Before the internal generator is removed ....................7 Measurement of generator A and B ......................8...
  • Page 60 BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 2.1: Location on the engine, TYPICAL 24–20–00 Effectivity: 912 i Series Rev. 0 Page 2 Edition 2 / June 01 2024...

  • Page 61: Special Tools

    BRP-Rotax MAINTENANCE MANUAL HEAVY SPECIAL TOOLS Description Part number Puller assy. 876010 Insertion jig 876020 Protection mushroom 876557 Locking pin 240880 n.a. Current measuring clamp n.a. Multimeter Figure 2.2: Special Tools Effectivity: 912 i Series 24–20–00 Rev. 0 Page 3...

  • Page 62: Service Products

    BRP-Rotax MAINTENANCE MANUAL HEAVY SERVICE PRODUCTS Description Part number LOCTITE 243 897651 LOCTITE 648 899788 LOCTITE 603 899789 LOCTITE 5910 899791 n. a. LOCTITE 7063 n. a. Engine oil n. a. Abrasive pad 24–20–00 Effectivity: 912 i Series Rev. 0...
  • Page 63 BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 2.3 Effectivity: 912 i Series 24–20–00 Rev. 0 Page 5 Edition 2 / June 01 2024...

  • Page 64: System Description

    BRP-Rotax MAINTENANCE MANUAL HEAVY SYSTEM DESCRIPTION SAFETY INSTRUCTION This ROTAX® aircraft engine has an electronically m WARNING controlled double-ignition system with an integrated generator. Danger of damage to engine! There is a risk of short circuits and cable fires during work on the electric system.

  • Page 65: Before The Internal Generator Is Removed

    BRP-Rotax MAINTENANCE MANUAL HEAVY BEFORE THE INTERNAL GENERATOR IS REMOVED NOTICE If these checks are omitted, it may be neces- sary to dismantle the product again to rectify any faults after repair work. General visual inspection. See Maintenance Manual Line (MML) for the respective engine type.

  • Page 66: Measurement Of Generator A And B

    BRP-Rotax MAINTENANCE MANUAL HEAVY MEASUREMENT OF GENERATOR A AND B General NOTE The engine must run during the measuring period (except resistance measurement) and the oil tem- perature must be > 80 °C (176 °F). m WARNING Danger of death due to high voltage!
  • Page 67 BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 2.5: Check voltage of generator A and B (Phase 1 to Phase 3) (Phase 1 to Phase 2) [Volts] [Volts] Engine speed [rpm] Average Min. Max. Min. Max. 2000 32.40 33.50 33.10 32.70 33.70 3000 50.00...
  • Page 68 BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 2.6: Diagram Current - measurement NOTE For this measurement the generator must not be disconnected from the regulators. NOTE All measurements must be performed at an engine speed from 2000 rpm to 5000 rpm in 1000 rpm steps.
  • Page 69 BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 2.7: Check current of generator A and B (Phase-1) [Amps] (Phase-2) [Amps] (Phase-3) [Amps] Engine speed [rpm] Max. Aver. Max. Max. Min. Min. Min. 2000 14.00 14.10 14.10 14.00 14.10 13.90 13.90 3000 13.80 13.80 13.80...
  • Page 70 BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 2.8: Diagram Resistance - measurement NOTE At resistance measurements the engine must not run. NOTE This measurement can also be done on a disassembled stator. Step Procedure Disconnect stator connectors A and B from the regulators on the fuse box.
  • Page 71 BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 2.9: Check resistance of generator A and B (Phase -1 to Phase (Phase -1 to Phase -3) (Phase -2 to Phase -3) Limit -2) [Ohms] [Ohms] [Ohms] GEN A GEN B 0.3 - 0.4 0.3 - 0.4 0.3 - 0.4...

  • Page 72: Removal

    BRP-Rotax MAINTENANCE MANUAL HEAVY REMOVAL Step Procedure Preparation Detach the electrical connection to the stator by disconnecting the connector (stator). NOTICE Press in the latch on the top of the con- Use appropriate protective coverings to prevent nector (Generator A Deutsch black and...
  • Page 73 BRP-Rotax MAINTENANCE MANUAL HEAVY Step Procedure Loosen 5 Allen screws M6x30 and 2 Allen screws M6x50 with washers 6.4. Disconnect Oil Pressure Sensor (OPS). Figure 2.11 Washer A 6.4 Lock. nut M6 Rubber buffer NOTE Push airbox upwards and wedge in place.

  • Page 74: Sealing Of The Plug Screws

    BRP-Rotax MAINTENANCE MANUAL HEAVY Step Procedure The plug screws must be removed and degreased for possible leaks. Secure plug screws with LOCTITE 243 and tighten it. Tightening torque 6 Nm (53 in.lb.). NOTICE Take care not to damage the oil seal contact surface in the ignition housing.

  • Page 75: Stator Assy. - Removal

    BRP-Rotax MAINTENANCE MANUAL HEAVY NOTE The location of the fly wheel does not have to be marked on the freehub body. Figure 2.18 Generator coil A Generator coil B (gray (black connector) connector) Figure 2.17: TYPICAL Fly wheel Allen screw Oil spray nozzle STATOR ASSY.
  • Page 76 BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 2.20 Figure 2.22 Connector Latch Cable Rubber seal Needle nose pliers Filler plug Step Procedure Stator connector B (AMPHENOL) - disassembly Bend back the retaining tab and at the NOTE same time carefully pull on the cable until Note the location and orientation of the cable the terminal is detached.
  • Page 77 BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 2.24 Allen screw Lock washer Cable clamp Figure 2.23 Connector cap Rubber seal Position letter Sleeve Key slot Procedure Step Unscrew Allen screw and remove with lock washer and cable clamps. Unscrew lock nut and remove the washer, disk springs and distance sleeve.
  • Page 78 BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 2.26 Figure 2.28 Adjustment screw Stator assy. Grommet M4x8 Step Procedure Remove the adjustment screw. Loosen 6 Allen screws with washers and remove stator assy. Figure 2.27 Allen screw M5x30 Washer A 5.5 Stator assy.

  • Page 79: Inspection

    BRP-Rotax MAINTENANCE MANUAL HEAVY INSPECTION IGNITION HOUSING — CHECK Clean all parts carefully. See current Main- tenance Manual Line (MML) for the re- spective engine type. Procedure Step Carry out visual inspection of sealing surfaces. Unscrew oil pressure sensor (OPS). To...

  • Page 80: Stator Assy. And Flywheel Assy. - Inspection

    BRP-Rotax MAINTENANCE MANUAL HEAVY Step Procedure Check the bearing bushing for damage and wear. Check that the oil bore is clear. Figure 2.32 Figure 2.33: TYPICAL Bearing bushing Oil bore Fly wheel assy. Stator assy. STATOR ASSY. AND FLYWHEEL ASSY.

  • Page 81: Wear Limits

    BRP-Rotax MAINTENANCE MANUAL HEAVY WEAR LIMITS AE 2iS_0675 Figure 2.34: Ignition housing Description Current measurement Tolerance Tolerance Code Measure- value limit limit ments 100 % 50 % Bearing bush- IH01 28.04 mm 28.05 mm 28.11 mm 28.08 mm current ing in ignition replaced 1.104 in.

  • Page 82: Assembly

    BRP-Rotax MAINTENANCE MANUAL HEAVY ASSEMBLY OIL SEAL — INSTALLATION IGNITION HOUSING — ASSEMBLY NOTICE All gaskets, O-rings and oil seals must be replaced! NOTE Polish and then clean the contact surface for the oil seal. OIL SEAL REPLACEMENT Figure 2.36...

  • Page 83: Stator Assy. - Installation

    BRP-Rotax MAINTENANCE MANUAL HEAVY Step Procedure Position the stator assy. Then secure 6 Allen screws M5x30 including washers A 5.5 with LOCTITE 243 and tighten them. Tightening torque 5 Nm (44 in.lb.). NOTE The separation paper of the two generator coils are in proximity with the water pump gear.

  • Page 84: Stator Connectors - Installation

    BRP-Rotax MAINTENANCE MANUAL HEAVY Install the distance sleeve, disk springs 15x5.2x0.7 and washer 5.1/15.5/2.5. Tighten new lock nut M5. Tightening torque 3 Nm (27 in. lb.) and then open counter-clockwise by 1.5 turns. Slip on the full length of the black protec- tion hoses.
  • Page 85 BRP-Rotax MAINTENANCE MANUAL HEAVY Part no. of con- Corresponding tool nector set 866420 (black) DEUTSCH HDT- 48 - 00 866422 (gray) DEUTSCH HDT- 48 - 00 Figure 2.44: TYPICAL Lock NOTE At malfunctions such as wire breakage and faulty plugs, the particular damage can be repaired.
  • Page 86 BRP-Rotax MAINTENANCE MANUAL HEAVY Step Procedure Install connector cap, push the rubber seal into the sleeve and push it onto the cables. Push each wire into connector until its pin snaps securely in place. Figure 2.46 Un-secured pin Secured pin...
  • Page 87 BRP-Rotax MAINTENANCE MANUAL HEAVY Step Procedure Install cable clamps 8/M6. NOTE The bends of the cable clamps must be installed in an opposed manner (back to back). Procedure Step Adjust cables. Tighten Allen screw M6x20 with lock washer A6. Tightening torque 10 Nm (89 in. lb.).

  • Page 88: Installation

    BRP-Rotax MAINTENANCE MANUAL HEAVY INSTALLATION IGNITION HOUSING ASSY. — INSTALLATION FLY WHEEL ASSY. — INSTALLATION Preparation NOTE • Check whether dowel pin has been inserted Clean all flat surfaces of the sprag clutch housing. Procedure Step Apply a small thin layer of LOCTITE 648 to the flat surface of the sprag clutch housing.
  • Page 89 BRP-Rotax MAINTENANCE MANUAL HEAVY m WARNING Danger of injury!The magnet of the fly wheel pulls the ignition cover towards the engine/ sealing surface with high force.Fingers can be crushed. Make sure screw of puller assy. is rotated inwards so the ignition cover is not pulled towards the engine.
  • Page 90 BRP-Rotax MAINTENANCE MANUAL HEAVY To install the crankshaft position sensor see Chapter 76-70-00 section . Fasten the ignition housing to the crank- case using 5 Allen screws M6x30 and 2 Allen screws M6x50 with Washers 6.4. Tightening torque 10 Nm (89 in. lb.).

  • Page 91: Finishing Work

    BRP-Rotax MAINTENANCE MANUAL HEAVY NOTE Unlock the crankshaft. See current Maintenance Manual Line No washers are used for these screws, as other- (MML) for the respective engine type, wise the starter does not lie flat on the flange Chapter 12-10-00 section Adding operat- surface.
  • Page 92 BRP-Rotax MAINTENANCE MANUAL HEAVY INTENTIONALLY LEFT BLANK Page 34 Effectivity: 912 i Series Edition 2 / June 01 2024 Rev. 0...
  • Page 93 BRP-Rotax MAINTENANCE MANUAL HEAVY Chapter: 24–30–00 EXTERNAL ALTERNATOR TOPICS IN THIS CHAPTER Tightening torque ............................3 System Description ..........................4 Drive ..............................4 Safety instruction...........................4 Maintenance ............................4 Before the external alternator is removed: ....................4 Removal ..............................5 V-belt pulley — removal .........................5 Alternator — Removal..........................5 Installation...............................7...
  • Page 94 BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 3.1: Location on the engine 24–30–00 Effectivity: 912 i Series Rev. 0 Page 2 Edition 2 / June 01 2024...

  • Page 95: Tightening Torque

    BRP-Rotax MAINTENANCE MANUAL HEAVY TIGHTENING TORQUE Figure 3.2 Effectivity: 912 i Series 24–30–00 Rev. 0 Page 3 Edition 2 / June 01 2024...

  • Page 96: System Description

    BRP-Rotax MAINTENANCE MANUAL HEAVY SYSTEM DESCRIPTION Carry out a generator inspection during an engine test run. See current Maintenance The ROTAX® 912 i Series can optionally be Manual Line (MML) for the respective en- equipped with an external alternator. This is a state- gine type, Chapter 12–20–00 section...

  • Page 97: Removal

    BRP-Rotax MAINTENANCE MANUAL HEAVY REMOVAL ALTERNATOR — REMOVAL Step Procedure Preparation Loosen 2 hex. screws along with lock Loosen pulley tension. See current Mainte- washers and washers. nance Manual Line (MML) for the respec- Remove the tension bar underneath the tive engine type.
  • Page 98 BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 3.7: Typical Figure 3.5: Typical Alternator support Washers assy. Hex. screw Thrust washer Lock washers Allen screws External alternator Step Procedure Loosen 2 Allen screws along with lock washers and remove the alternator bracket. Figure 3.6: Typical...

  • Page 99: Installation

    BRP-Rotax MAINTENANCE MANUAL HEAVY INSTALLATION V-BELT PULLEY — INSTALLATION Step Procedure Push the V-belt pulley completely over the propeller flange and insert the V-belt 9.5x675 loosely into the V-belt pulley. Figure 3.9: Typical Allen screws M5x16 Lock washers A5 Pulley carrier V-belt pulley ALTERNATOR —...
  • Page 100 BRP-Rotax MAINTENANCE MANUAL HEAVY Step Procedure Attach the alternator bracket finger-tight to the gearbox housing using the 2 Allen screws M8x20 and lock washers VHZ8. Figure 3.12: Typical Thrust washer 10.1/20/ Alternator Hex. screw M10x45 Alternator bracket Figure 3.11: Typical...

  • Page 101: V-Belt Tension

    BRP-Rotax MAINTENANCE MANUAL HEAVY Step Procedure Adjust the pulley tension and tighten hex. screws M10 and M8. Tightening torque hex. screws M10: 40 Nm (30 ft. lb.) Tight- ening torque hex. screws M8: 22 Nm (16 ft. lb.). See relevant Maintenance Manual Line (MML) for the respective engine type.
  • Page 102 BRP-Rotax MAINTENANCE MANUAL HEAVY INTENTIONALLY LEFT BLANK Page 10 Effectivity: 912 i Series Edition 2 / June 01 2024 Rev. 0...
  • Page 103 BRP-Rotax MAINTENANCE MANUAL HEAVY Chapter: 37–10–00 VACUUM PUMP TOPICS IN THIS CHAPTER Special tools............................3 Service Products .............................4 System description ..........................6 Safety Instruction ..........................6 Maintenance ............................6 Removal ..............................7 Vacuum pump — removal ........................7 Inspection .............................10 Drive sleeve — inspection ........................10 Vacuum pump gear - inspection......................10 Vacuum pump —...
  • Page 104 BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 4.1: Location on the engine 37–10–00 Effectivity: 912 i Series Rev. 0 Page 2 Edition 2 / June 01 2024...

  • Page 105: Special Tools

    BRP-Rotax MAINTENANCE MANUAL HEAVY SPECIAL TOOLS Description Part number Insertion jig assy. 276332 Retaining tool 242661 Ring spanner a/f 10/13 876470 Puller assy. 876489 Press-in mushroom 877597 Press-in mushroom 877595 Insertion jig assy. 877276 Figure 4.2: Special tools Effectivity: 912 i Series 37–10–00...

  • Page 106: Service Products

    BRP-Rotax MAINTENANCE MANUAL HEAVY SERVICE PRODUCTS Description Part number n.a. Engine oil LOCTITE 243 897651 LOCTITE 648 899788 37–10–00 Effectivity: 912 i Series Rev. 0 Page 4 Edition 2 / June 01 2024...
  • Page 107 BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 4.3: Vacuum pump Effectivity: 912 i Series 37–10–00 Rev. 0 Page 5 Edition 2 / June 01 2024...

  • Page 108: System Description

    BRP-Rotax MAINTENANCE MANUAL HEAVY SYSTEM DESCRIPTION There is the option of installing a vacuum pump. To do this, the drive for the vacuum pump must be retro- fitted in the propeller gearbox. NOTE Simultaneous use of the vacuum pump and gov- ernor is not possible.

  • Page 109: Removal

    BRP-Rotax MAINTENANCE MANUAL HEAVY REMOVAL VACUUM PUMP — REMOVAL Preparation General visual inspection. See current Maintenance Manual Line (MML) for the respective engine type. Carry out a functional test run to identify any damage. See "Documentation of air- craft manufacturer".
  • Page 110 BRP-Rotax MAINTENANCE MANUAL HEAVY NOTICE The M8 fastening screw for the vacuum pump gear is 14 mm (0.55 in.) long with a normal screw head in the vacuum pump drive. Figure 4.7 Retaining washer Countersunk screw Step Procedure Lift out the oil seal and press the needle...
  • Page 111 BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 4.9 Insertion jig 276332 NOTE The needle sleeve, oil seal and ball bearing are damaged by this and must be replaced. Effectivity: 912 i Series 37–10–00 Rev. 0 Page 9 Edition 2 / June 01 2024...

  • Page 112: Inspection

    BRP-Rotax MAINTENANCE MANUAL HEAVY INSPECTION Preparation Clean all parts carefully. See current Main- tenance Manual Line (MML) for the re- spective engine type. General visual inspection. See current Maintenance Manual Line (MML) for the respective engine type. Figure 4.11 DRIVE SLEEVE — INSPECTION...

  • Page 113: Installation

    BRP-Rotax MAINTENANCE MANUAL HEAVY INSTALLATION NOTICE For installation of needle sleeve and ball bearing see The M8 fastening screw for the vacuum pump Chapter 61–20–00. gear is 14 mm (0.55 in.) long with a normal screw head in the vacuum pump drive.

  • Page 114: Finishing Work

    BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 4.14 Figure 4.15 Studs M6 Vacuum pump Gasket Attachment flange Studs M6 NOTICE The gear-tooth system of the governor must match when installed! NOTICE No hammering or pressing! The drive gear must only be pushed on by hand.
  • Page 115 BRP-Rotax MAINTENANCE MANUAL HEAVY Fill with operating fluids or check filling levels. See current Maintenance Manual Line (MML) for the respective engine type, Chapter 12-10-00 section Adding operat- ing fluids. Carry out an engine test run. See current Maintenance Manual Line...
  • Page 116 BRP-Rotax MAINTENANCE MANUAL HEAVY INTENTIONALLY LEFT BLANK Page 14 Effectivity: 912 i Series Edition 2 / June 01 2024 Rev. 0...
  • Page 117 BRP-Rotax MAINTENANCE MANUAL HEAVY Chapter: 61–20–00 GOVERNOR TOPICS IN THIS CHAPTER Special tools............................3 Service Products .............................4 System description ..........................6 Safety instruction...........................6 Maintenance ............................6 Removal ..............................7 Governor – removal ..........................7 Governor flange — removal ........................7 Governor drive — removal ........................8 Roller bearing configuration 3 — removal ....................9 Inspection .............................10...
  • Page 118 BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 5.1: Location on the engine 61–20–00 Effectivity: 912 i Series Rev. 0 Page 2 Edition 2 / June 01 2024...

  • Page 119: Special Tools

    BRP-Rotax MAINTENANCE MANUAL HEAVY SPECIAL TOOLS Description Part number Extractor assy. 877615 Puller 876489 Insertion jig assy. 276332 Retaining device 242661 Ring spanner a/f 10/13 876470 Press-in mushroom 877595 Press-in mushroom 877597 Press-in mushroom 877590 Figure 5.2: Special tools Effectivity: 912 i Series 61–20–00...

  • Page 120: Service Products

    BRP-Rotax MAINTENANCE MANUAL HEAVY SERVICE PRODUCTS Description Part number LOCTITE 243 897651 LOCTITE 648 899788 LOCTITE ANTI SEIZE 297434 n.a. Engine oil 61–20–00 Effectivity: 912 i Series Rev. 0 Page 4 Edition 2 / June 01 2024...
  • Page 121 BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 5.3 Effectivity: 912 i Series 61–20–00 Rev. 0 Page 5 Edition 2 / June 01 2024...

  • Page 122: System Description

    BRP-Rotax MAINTENANCE MANUAL HEAVY SYSTEM DESCRIPTION SAFETY INSTRUCTION For operation with a hydraulic constant-speed pro- m WARNING peller on configuration 3 of the engine type 912 i Ser- ies, a hydraulic governor can be attached to control Follow the general safety instructions during the propeller.

  • Page 123: Removal

    BRP-Rotax MAINTENANCE MANUAL HEAVY REMOVAL GOVERNOR – REMOVAL Preparation General visual inspection. See current Maintenance Manual Line (MML) for the respective engine type. Carry out engine test run to check proper functioning of the governor. See current Maintenance Manual Line (MML) for the respective engine type.

  • Page 124: Governor Drive - Removal

    BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 5.7 Governor flange Allen screws O-ring O-ring Spacer GOVERNOR DRIVE — REMOVAL CONFIGURATION 3 Preparation • The propeller gearbox must be removed so that the governor drive can be removed. See current Figure 5.6 Maintenance Manual Line (MML) of the respective engine type.
  • Page 125 BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 5.9 Thrust washer Countersunk screw Figure 5.8 Retaining tool 242661 Drive sleeve and 876470 Vacuum pump gear Allen screw Procedure Step Loosen the countersunk screw with thrust washer for the ball bearing fastening. Press the needle sleeve along with the ball bearing out towards the gearbox with a suitable insertion jig part no.

  • Page 126: Inspection

    BRP-Rotax MAINTENANCE MANUAL HEAVY INSPECTION NOTE GOVERNOR - INSPECTION Wear usually appears as a flattened area on the journal. NOTICE Step Procedure Follow the governor manufacturer's instruc- Check the gear-tooth system of the drive tions for maintenance, inspection and repair.
  • Page 127 BRP-Rotax MAINTENANCE MANUAL HEAVY Step Procedure Check the toothing of the drive sleeve for damage.. Figure 5.14 Effectivity: 912 i Series 61–20–00 Rev. 0 Page 11 Edition 2 / June 01 2024...

  • Page 128: Wear Limits

    BRP-Rotax MAINTENANCE MANUAL HEAVY WEAR LIMITS Figure 5.15: Propeller gearbox For detailed information and measurements, see Chapter 72-10-00 section Wear limits (Gearbox). 61–20–00 Effectivity: 912 i Series Rev. 0 Page 12 Edition 2 / June 01 2024...

  • Page 129: Installation

    BRP-Rotax MAINTENANCE MANUAL HEAVY INSTALLATION BALL BEARING — INSTALLATION Step Procedure NOTICE Apply puller part no. 876489 on the gov- All gaskets, O-rings and oil seals must be ernor side. replaced! Insert the press-in mushroom part no. 877595 into the roller bearing and fix it NEEDLE SLEEVE –...

  • Page 130: Roller Bearing Configuration 3 - Installation

    BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 5.18 Countersunk screw Figure 5.19: Typical Thrust washer M5x12 Retaining tool 242660 Drive sleeve ROLLER BEARING CONFIGURATION 3 and 876470 — INSTALLATION Vacuum pump gear Allen screw M8x16 Chapter 72-10-00 section Propeller gearbox. GOVERNOR FLANGE — INSTALLATION GOVERNOR DRIVE —...
  • Page 131 BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 5.20: TYPICAL Figure 5.21 O-ring 32x4 Governor flange Distance sleeve Allen screw M6x20 O-ring 7x2 Allen screw M6x16 NOTICE NOTICE Longer screws may destroy the oil inlet flange Leakage may occur, if LOCTITE 243 sticks the and bearings.

  • Page 132: Governor Installation

    BRP-Rotax MAINTENANCE MANUAL HEAVY Step Procedure Secure the 2 plug screw M8x1 with LOC- TITE 243. Tightening torque 10 Nm (89 in.lb.) Figure 5.22 Figure 5.24 Governor flange Plug screws M8x1 Step Procedure Check that the studs are firmly in place. If necessary, apply LOCTITE 243 and tight- en.

  • Page 133: Finishing Work

    BRP-Rotax MAINTENANCE MANUAL HEAVY NOTICE The gear-tooth system of the governor must match when installed! NOTE Make sure that the gearing is engaged and the geared shaft of the governor move easily into the drive sleeve. NOTICE No hammering or pressing! The drive gear must only be pushed on by hand.
  • Page 134 BRP-Rotax MAINTENANCE MANUAL HEAVY INTENTIONALLY LEFT BLANK Page 18 Effectivity: 912 i Series Edition 2 / June 01 2024 Rev. 0...
  • Page 135 BRP-Rotax MAINTENANCE MANUAL HEAVY Chapter: 71–00–00 POWER PLANT TOPICS IN THIS CHAPTER Special tools............................3 Service products .............................4 Installation checklist ..........................5 General Note ............................8 Delivery of the engine ..........................8 Engine preservation..........................8 Return to service ..........................10 Treating rust and surface damage......................10 System description ..........................11 Description of design ...........................
  • Page 136 BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 6.1: Power plant 71–00–00 Effectivity: 912 i Series Rev. 0 Page 2 Edition 2 / June 01 2024...

  • Page 137: Special Tools

    BRP-Rotax MAINTENANCE MANUAL HEAVY SPECIAL TOOLS Description Part number Engine lifting kit assy. 876040 Trestle support 877930 Trestle adapter assy. 876050 Socket driver hex. 8 ball head 876240 Figure 6.2: Special tools Effectivity: 912 i Series 71–00–00 Rev. 0 Page 3...

  • Page 138: Service Products

    BRP-Rotax MAINTENANCE MANUAL HEAVY SERVICE PRODUCTS Description Part number LOCTITE 243 897651 LOCTITE 648 899788 71–00–00 Effectivity: 912 i Series Rev. 0 Page 4 Edition 2 / June 01 2024...

  • Page 139: Installation Checklist

    Registration number Manufacturer Engine Type Serial number FUSE BOX serial number ECU part no. (S/N) Manufacturer BRP-Rotax GmbH&Co KG, 4623 Gunskirchen, Austria Specifications/version Miscellaneous data Installation date Mechanic (surname and forename) Installation-related point Remark Control unit (ECU) checked for damage and corro- sion.
  • Page 140 BRP-Rotax MAINTENANCE MANUAL HEAVY Installation-related point Remark All fuel tanks and fuel lines cleaned. See “Documentation of aircraft manufacturer”. See relevant Maintenance Manual Line (MML) Chapter 12–20–00 Planned maintenance. Checking the engine for contamination and damage. See relevant Maintenance Manual Line (MML) Chapter 05–00–00 Maintenance.
  • Page 141 BRP-Rotax MAINTENANCE MANUAL HEAVY Installation-related point Remark Cooling system flushed and filled. To do this see relevant Maintenance Manual Line (MML) Chapter 12–10–00 section Adding operat- ing fluids + Chapter 12-20-00 section Flushing the engine cooling system. Engine test run/functional test.

  • Page 142: General Note

    BRP-Rotax MAINTENANCE MANUAL HEAVY GENERAL NOTE Removal of protective coverings and preservation DELIVERY OF THE ENGINE Procedure Step Delivery and handling of the engine and assemblies Remove protective coverings, waxed pa- per or something similar. • When the engine is delivered, check that the origi- nal ROTAX®...
  • Page 143 Flush the engine cooling system. correctly also is in the responsibility of the pre- See current Maintenance Manual Line vious named parties. BRP-Rotax can not ap- (MML) for the respective engine type, prove, if a preservation was done correctly or Chapter 12-20-00 section Flushing the en- not.If no documentation of preservation is...

  • Page 144: Return To Service

    BRP-Rotax MAINTENANCE MANUAL HEAVY stored and inactive aircraft (engines) provides an ef- See current Maintenance Manual Line fective means for combating and minimizing the cor- (MML) for the respective engine type, rosion condition and should be adhered to. Chapter 12-20-00, section “Planned maintenance”.

  • Page 145: System Description

    BRP-Rotax MAINTENANCE MANUAL HEAVY SYSTEM DESCRIPTION NOTE DESCRIPTION OF DESIGN If additional parts are purchased, part of the se- rial and part numbering of the aeronautical A ROTAX® 912 i Series engine consists equipment manufacturer is included. basically of several main components and...

  • Page 146: Engine/Components, General

    BRP-Rotax MAINTENANCE MANUAL HEAVY ENGINE/COMPONENTS, GENERAL Integrated 2 permanent magnet 3-phase gener- generator ators. 200 and 400 W. Design 4–cylinder normal aspirated engine Regulator 12 V 20 A DC Bore 84 mm (3.31 in.) External Full-wave rectifier with 12 V 40 A DC Stroke 61.0 mm (2.40 in.)

  • Page 147: Engine Components, Engine Views, Cylinder Designation And Definition Of Main Axis

    BRP-Rotax MAINTENANCE MANUAL HEAVY ENGINE COMPONENTS, ENGINE VIEWS, CYLINDER DESIGNATION AND DEFINITION OF MAIN AXIS Power take off side Magneto side Attachment points (for engine transport) @ @ , Z Center of gravity Zero reference point (starting point for all dimensions) NOTE Allow ±...
  • Page 148 BRP-Rotax MAINTENANCE MANUAL HEAVY Components, engine views Figure 6.5: Side view Engine serial number Propeller flange Propeller gearbox Ignition housing Engine suspension frame (optional) Water pump housing Muffler assy. 71–00–00 Effectivity: 912 i Series Rev. 0 Page 14 Edition 2 / June 01 2024...
  • Page 149 BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 6.6: front view Oil pump housing Oil filter Fuel rail left/right Fuel hose assy. Connection for oil feed line Connection for oil return line Effectivity: 912 i Series 71–00–00 Rev. 0 Page 15 Edition 2 / June 01 2024...
  • Page 150 BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 6.7: top view Intake manifold, left (cyl. 1/3), right (cyl. 2/4) Expansion tank assy. Electric starter assy. Airbox Fuel pressure regulator Fuel pump module assy. Oil tank assy. Connection for fuel return line Connection for fuel feed line 71–00–00...

  • Page 151: Maintenance

    BRP-Rotax MAINTENANCE MANUAL HEAVY MAINTENANCE For maintenance and special checks, see Maintenance Manual Line (MML) for the respective engine type. Effectivity: 912 i Series 71–00–00 Rev. 0 Page 17 Edition 2 / June 01 2024...

  • Page 152: Power Plant

    BRP-Rotax MAINTENANCE MANUAL HEAVY POWER PLANT Drain the coolant. See current Mainte- nance Manual Line (MML) for the respec- SAFETY INSTRUCTION tive engine type, Chapter 12-20-00 section Planned maintenance. m WARNING Danger of severe burns and scalds! Always al- Drain the fuel. See current Maintenance...

  • Page 153: Removal Of The Power Plant From The Aircraft

    BRP-Rotax MAINTENANCE MANUAL HEAVY NOTICE For removal and installation of the power plant proceed according to the aircraft manufac- turer’s instructions. POWER PLANT – INSTALLATION Install the feed line of fuel rail 1/3 and re- turn line of fuel rail 2/4 and fuel pressure regulator.
  • Page 154 BRP-Rotax MAINTENANCE MANUAL HEAVY Fill with operating fluids or check filling lev- els. See current Maintenance Manual Line (MML) for the respective engine type, Chapter 12–10–00 section Adding operat- ing fluids. Purge the oil system. See current Installa- tion Manual (IM) for the respective engine type, Chapter 79-00-00 section Purging the lubrication system.

  • Page 155: Trestle Adapter Assy. - Installation And Removal

    BRP-Rotax MAINTENANCE MANUAL HEAVY TRESTLE ADAPTER ASSY. – INSTALLATION AND REMOVAL m WARNING Danger of injury due to falling parts!When the engine is removed there is a risk of injury due to the engine or its assemblies falling! Use ROTAX lift set, no other lifting points allowed.

  • Page 156: Trestle Adapter Assy. - Removal

    BRP-Rotax MAINTENANCE MANUAL HEAVY NOTICE Make sure that no foreign bodies get into con- nected lines and connections. Procedure Step Install plug screw M16x1.5 with a new sealing ring 16x22 and LOCTITE 243 or adapter (metric or UNF) with a new seal- ing ring 16x22 and LOCTITE 648.

  • Page 157: Finishing Work

    BRP-Rotax MAINTENANCE MANUAL HEAVY Install surrounding components according to the aircraft manufacturer’s instructions. Fill with operating fluids or check filling levels. See current Maintenance Manual Line (MML) for the respective engine type, Chapter 12-10-00 section Adding operat- ing fluids. Flush the engine cooling system.

  • Page 158: Removal

    BRP-Rotax MAINTENANCE MANUAL HEAVY REMOVAL ENGINE SUSPENSION FRAME — REMOVAL m WARNING Danger of severe burns and scalds! Always allow the engine to cool down to ambient temperature before starting any work. Drain the coolant. See current Maintenance Manual Line (MML) for the respective engine type.
  • Page 159 BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 6.15 Figure 6.13 Engine suspension Allen screw M10x35 Engine suspension Thrust washer frame with lock washer frame NOTE NOTICE Remove the air filter including the heat shield Do not damage the Coolant Temperature Sen- according to the aircraft manufacturer’s sor (CTS) and Exhaust Temperature Sensor instructions.

  • Page 160: Inspection

    BRP-Rotax MAINTENANCE MANUAL HEAVY INSPECTION ENGINE SUSPENSION FRAME — INSPECTION Step Procedure All components must be visually inspected. NOTE Detailed visual inspection of the engine suspen- sion frame in the vicinity of all welded connec- tions between the tube and the struts.

  • Page 161: Installation

    BRP-Rotax MAINTENANCE MANUAL HEAVY INSTALLATION • Install muffler, if necessary. See Chapter 78-10-00 section Exhaust assy. — installation. ENGINE SUSPENSION FRAME — INSTALLATION • Install the coolant hoses (feed and return) accord- ing to the aircraft manufacturer’s instructions. NOTICE Fill with operating fluids or check filling The engine suspension frame must be in- levels.
  • Page 162 BRP-Rotax MAINTENANCE MANUAL HEAVY INTENTIONALLY LEFT BLANK Page 28 Effectivity: 912 i Series Edition 2 / June 01 2024 Rev. 0...
  • Page 163 BRP-Rotax MAINTENANCE MANUAL HEAVY Chapter: 72–00–00 ENGINE TOPICS IN THIS CHAPTER System description ..........................3 Safety instruction...........................3 Crankshaft distortion — inspection ......................4 Finishing work ............................6 Wear limits ..............................8 This section describes the maintenance of the ROTAX® 912 i Series engine. The description is divided into subsections and explanations of system functions.
  • Page 164 BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 7.1: Engine 72–00–00 Effectivity: 912 i Series Rev. 0 Page 2 Edition 2 / June 01 2024...

  • Page 165: System Description

    BRP-Rotax MAINTENANCE MANUAL HEAVY SYSTEM DESCRIPTION The 912 i Series engine is a 4-cylinder, four-stroke, horizontally opposed engine with manifold injection. This engine has liquid cooled cylinder heads and ram air cooled cylinders; this engine also has a fully redundant, electronic engine management system (EMS) including fuel injection, map-controlled ignition etc.
  • Page 166 BRP-Rotax MAINTENANCE MANUAL HEAVY CRANKSHAFT DISTORTION — NOTICE INSPECTION Do not damage the crankshaft Preparation Step Procedure Drain oil. See current Maintenance Manual Carefully mount bushing for gauge block Line (MML) for the respective engine type. onto the crankshaft. Install the indicator between the ball bear- Remove the propeller gearbox.
  • Page 167 BRP-Rotax MAINTENANCE MANUAL HEAVY NOTE On all 4 cylinders the piston stopper has to be installed in the upper spark plug thread. NOTE Make sure that the piston stopper has been screwed in completely – so there is no space between the spark plug hole and the tooling surface.

  • Page 168: Finishing Work

    BRP-Rotax MAINTENANCE MANUAL HEAVY Example showing the results from measuring a NOTICE crankshaft, where the GB20 threshold is not exceeded. Values can always be positive or negative, which is very important for the whole Cylinder Deviation – good measurement. 0°...
  • Page 169 BRP-Rotax MAINTENANCE MANUAL HEAVY Carry out an engine test run. See current Maintenance Manual Line (MML) for the respective engine type, Chapter 12-20-00 section Planned maintenance. Effectivity: 912 i Series 72–00–00 Rev. 0 Page 7 Edition 2 / June 01 2024...

  • Page 170: Wear Limits

    BRP-Rotax MAINTENANCE MANUAL HEAVY WEAR LIMITS Descrip- Reading new Wear limit Code tion Readings max. min. 100 % 50 % CRANKSHAFT Cyl. 1 Cyl. 2 Cyl. 3 Cyl. 4 Crank- GB20 actual shaft (degrees) (degrees) renewed angle of twist 72–00–00 Effectivity: 912 i Series Rev.
  • Page 171 BRP-Rotax MAINTENANCE MANUAL HEAVY Chapter: 72–10–00 PROPELLER GEARBOX TOPICS IN THIS CHAPTER Special tools............................3 Service products .............................4 System description ..........................6 Safety instructions ..........................6 Maintenance ............................6 Removal ..............................7 Disassembly............................8 Disassembly of the propeller gearbox .....................8 Removal of the propeller shaft ........................9 Removal of the ball bearing ........................10...
  • Page 172 BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 8.1: Location on the engine 72–10–00 Effectivity: 912 i Series Rev. 0 Page 2 Edition 2 / June 01 2024...

  • Page 173: Special Tools

    BRP-Rotax MAINTENANCE MANUAL HEAVY SPECIAL TOOLS Description Part number n.a. Hot air gun Socket wrench assy. 41x12.5 877445 Mounting yoke to compress dog gear 876885 n.a. Circlip pliers Extractor 877615 877605 Press-out mushroom (configuration 2) Press-out mushroom (configuration 3) 877600...

  • Page 174: Service Products

    BRP-Rotax MAINTENANCE MANUAL HEAVY SERVICE PRODUCTS Description Part number n.a. Engine oil LOCTITE 243 897651 LOCTITE 648 899788 899791 LOCTITE 5910 LOCTITE 7063 LITHIUM-BASE GREASE 897330 LOCTITE ANTI SEIZE 297434 n.a. Abrasive pad 72–10–00 Effectivity: 912 i Series Rev. 0...
  • Page 175 BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 8.3 Effectivity: 912 i Series 72–10–00 Rev. 0 Page 5 Edition 2 / June 01 2024...

  • Page 176: System Description

    BRP-Rotax MAINTENANCE MANUAL HEAVY SYSTEM DESCRIPTION SAFETY INSTRUCTIONS The propeller shaft is driven by the crankshaft by m WARNING means of a linear helical gear unit. Gear ratio crank- shaft : propeller shaft 2.43 : 1. Danger of severe burns and scalds!

  • Page 177: Removal

    BRP-Rotax MAINTENANCE MANUAL HEAVY REMOVAL For removal of the propeller gearbox, see current Maintenance Manual Line (MML) for the respective engine type. For removal of the drive gear, see current Maintenance Manual Line (MML) for the respective engine type. Preparation Before the propeller gearbox is removed, the gear- box oil line assy.

  • Page 178: Disassembly

    BRP-Rotax MAINTENANCE MANUAL HEAVY DISASSEMBLY Step Procedure DISASSEMBLY OF THE PROPELLER Relieve the pressure on the gear. GEARBOX Remove mounting yoke and the gearbox from the fixture. NOTICE Remove the drive gear, the thrust washer Gearbox housing may be damaged.

  • Page 179: Removal Of The Propeller Shaft

    BRP-Rotax MAINTENANCE MANUAL HEAVY NOTICE The overload clutch is built in as standard in all certified and non-certified aircraft engines. Figure 8.8: Propeller gearbox with oil spray nozzle Clutch assy. Disc springs Compensating shim Step collar (as required) Figure 8.7: Propeller gearbox without oil spray...

  • Page 180: Removal Of The Ball Bearing

    BRP-Rotax MAINTENANCE MANUAL HEAVY Step Procedure NOTICE Screw the extractor part no. 877615 onto The shaft seal will be damaged in this process the gearbox housing with six Allen screws and must therefore be replaced. M6x25 and place press-out mushroom part no.

  • Page 181: Blinding Shim - Removal

    BRP-Rotax MAINTENANCE MANUAL HEAVY BLINDING SHIM - REMOVAL CONFIGURATION 2 Procedure Step Loosen the countersunk screw with thrust washer for the blinding shim fastening. Press the blinding shim out towards the gearbox with the insertion jig part no. 276332. Figure 8.11: Propeller gearbox with oil spray nozzle Hex.

  • Page 182: Removal Of The Roller Bearing - Configuration 2

    BRP-Rotax MAINTENANCE MANUAL HEAVY REMOVAL OF THE ROLLER BEARING — CONFIGURATION 2 Preparation • If necessary remove the vacuum pump gear. See Chapter 37-10-00 section Vacuum pump — removal. Remove propeller gearbox. See current Maintenance Manual Line (MML) for the respective engine type.
  • Page 183 BRP-Rotax MAINTENANCE MANUAL HEAVY Preparation • Remove the governor flange. See Chapter 61-20- • Remove the vacuum pump gear: See Chapter 37- 10-00 section Vacuum pump gear. NOTICE The pressing out process for configuration 3 with the hydraulic governor is different from that for configurations 2.

  • Page 184: Inspection

    BRP-Rotax MAINTENANCE MANUAL HEAVY INSPECTION PROPELLER GEARBOX SINGLE PARTS — INSPECTION Preparation Clean all parts carefully. See current Main- tenance Manual Line (MML) for the re- spective engine type. General visual inspection. See current Maintenance Manual Line (MML) for the respective engine type.

  • Page 185: Propeller Shaft - Inspection

    BRP-Rotax MAINTENANCE MANUAL HEAVY PROPELLER SHAFT — INSPECTION Step Procedure Inspect the oil spray nozzle for blockage NOTICE and bending. Check the correct position of the jet. The entire propeller shaft including fastening bores must be free from corrosion; there must Inspect that the bearing bushing for sup- be no fretting corrosion at the bearing points.

  • Page 186: Dog Hub - Inspection

    BRP-Rotax MAINTENANCE MANUAL HEAVY Step Procedure Check the groove for the retaining rings and gear-tooth system for wear and damage. Figure 8.23 Treatment of corrosion damage and surface dam- age on the propeller flange. Chapter 72–10–00 section Wear limits. The flange of the propeller shaft is susceptible to flash rust.

  • Page 187: Thrust Washer, Bearing Bushing - Inspection

    BRP-Rotax MAINTENANCE MANUAL HEAVY Step Procedure Measure the gap between the cam peak and the cam trough; see Chapter 72-10- 00 section Wear limits (GB07) NOTE Slight to moderate traces of wear and pitting on the dogs are permissible. Figure 8.25...

  • Page 188: Checking The Splines

    BRP-Rotax MAINTENANCE MANUAL HEAVY NOTICE Check all the tooth flanks for any damage or pitting. NOTE If the gearbox is installed, it is also possible to check the gear set using an endoscope. This must be done in such a manner that an exact assessment of the tooth flanks is possible and requires experience.

  • Page 189: Pitting, General Information

    BRP-Rotax MAINTENANCE MANUAL HEAVY PITTING, GENERAL INFORMATION prevent pits which have already formed from developing. NOTE Conclusion: When pitting occurs it is necessary to distin- These pits are not important for safe operation. The guish between tolerable initial pitting and gear set can still be used.

  • Page 190: Destructive Pitting

    BRP-Rotax MAINTENANCE MANUAL HEAVY DESTRUCTIVE PITTING Features: Extensive flank fractures, generally occurring as zones of pitting. The bottom of the fracture generally has a mussel-shaped structure. The total pitting area can be so great that the running smoothness is no-...

  • Page 191: Flake Pitting (Large-Area Flank Fractures)

    BRP-Rotax MAINTENANCE MANUAL HEAVY Causes: This pattern of damage generally occurs at low oper- ating oil viscosities and/or high oil temperatures. Apart from these, the same causes apply as for pitting. Figure 8.31: Magnification approx. 1.5x. Pit formation in the root region of a spur gear tooth...

  • Page 192: Wear Limits

    BRP-Rotax MAINTENANCE MANUAL HEAVY WEAR LIMITS Figure 8.34 72–10–00 Effectivity: 912 i Series Rev. 0 Page 22 Edition 2 / June 01 2024...
  • Page 193 BRP-Rotax MAINTENANCE MANUAL HEAVY Description Reading new Wear limit Code Read- ings max. min. 100 % 50 % Propeller gearbox Bearing bushing in gear cover Bore GB01 28.04 mm 28.05 mm 28.10 mm 28.075 mm actual 1.1035 in 1.1039 in 1.1063 in...

  • Page 194: Propeller Gearbox

    BRP-Rotax MAINTENANCE MANUAL HEAVY PROPELLER GEARBOX 09581 Figure 8.35 Description Reading new Wear limit Code Readings 100 % 50 % Tooth profile Crankshaft CS07 0.95 mm 1.00 mm 0.80 mm 0.88 mm actual 0.0374 in 0.0374 in. 0.0315 in. 0.0344 in.
  • Page 195 BRP-Rotax MAINTENANCE MANUAL HEAVY Description Reading new Wear limit Code Readings 100 % 50 % renewed Pitting on dog actual 2.5% gear up to 5 % renewed Gear backlash GB18 0.07 mm 0.15 mm 0.20 mm 0.18 mm actual 0.003 in.

  • Page 196: Assembly

    BRP-Rotax MAINTENANCE MANUAL HEAVY ASSEMBLY Step Procedure OIL SPRAY NOZZLE — INSTALLATION Press new oil seal AS 40x55x7 into the gearbox housing from the inside using in- Step Procedure sertion jig part no. 876518. Insert the oil spray nozzle assy.

  • Page 197: Propeller Shaft - Installation

    BRP-Rotax MAINTENANCE MANUAL HEAVY Step Procedure Press on the gearbox housing with a slight turning movement. NOTE It is advantageous when the gearbox housing is still warm. Figure 8.37: Propeller gearbox with oil spray nozzle Hex. screw M7x16 Washer 7.2/18.8/3 Ball bearing Radius ring 36/50/5.5...
  • Page 198 BRP-Rotax MAINTENANCE MANUAL HEAVY With clutch Step Procedure Lubricate 2 disc springs (lying against each other) along with step collar with a diameter of 40.8 mm (1.6 in.) facing the disc spring with lithium-base grease and push them on. NOTE...

  • Page 199: Adjustment Of The Disc Spring Pretension

    BRP-Rotax MAINTENANCE MANUAL HEAVY NOTICE The thrust washer must be replaced every repair. NOTICE The contact surface of the plastic thrust wash- er must be level (flat). Risk of breakage! Figure 8.41: Typical Bearing bushing Propeller shaft Step Procedure Push on the gear (propeller shaft).

  • Page 200: Assembly Of The Propeller Gearbox Assy

    BRP-Rotax MAINTENANCE MANUAL HEAVY NOTE Step Procedure When the propeller shaft assembly is not ten- Place the whole gearbox in a suitable sioned, the contact face for the ring halves must fixture. lie 1 mm (0.039 in.) above the upper edge in the Press down the gear (propeller shaft) with groove of the propeller shaft.

  • Page 201: Installation

    BRP-Rotax MAINTENANCE MANUAL HEAVY INSTALLATION BLINDING SHIM – INSTALLATION CONFIGURATION 2 Step Procedure Install new O-ring 26.7x1.8 onto the blind- ing shim. Apply LOCTITE 5910 where the O-ring contacts the crankcase splitting line. Install the blinding shim with the full side into the crankcase.
  • Page 202 BRP-Rotax MAINTENANCE MANUAL HEAVY ROLLER BEARING – INSTALLATION (CONFIGURATION 3) NOTICE The oil inlet flange must not be installed tilted and the O-ring must be not pinched. Step Procedure Lubricate a new O-ring with engine oil and push it into the crankcase with the oil inlet flange.

  • Page 203: Finishing Work

    BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 8.50 Figure 8.51 Governor flange Press-in mushroom Extractor part no. Allen screws M6x20 part no. 877590 877615 Allen screws M6x16 Roller bearing Step Procedure Install the extractor part no. 877615 with 6 Allen screws M6x25 onto the crank- case, place the press-in mushroom part no.
  • Page 204 BRP-Rotax MAINTENANCE MANUAL HEAVY Fill with operating fluids or check filling levels. See current Maintenance Manual Line (MML) for the respective engine type, Chapter 12-10-00 section Adding operat- ing fluids. Purge the oil system. See current Installation Manual (IM) for the respective engine type, Chapter 79-00-00 section Purging the lubrication system.
  • Page 205 BRP-Rotax MAINTENANCE MANUAL HEAVY Chapter: 72–20–00 ENGINE BLOCK TOPICS IN THIS CHAPTER Special tools............................2 Service products .............................3 General note ............................5 Safety instructions ..........................5 Maintenance ............................5 Removal ..............................6 Sprag clutch — removal .........................6 Sprag clutch housing – removal......................6 Disassembly............................9 Disassembling the sprag clutch housing....................9 Inspection .............................10...

  • Page 206: Special Tools

    BRP-Rotax MAINTENANCE MANUAL HEAVY SPECIAL TOOLS Description Part number n.a. Hot air gun Puller 877375 n.a. Seeger ring pliers n.a. Free wheel gear axial clearance measuring fixture 38x20 insert for SW32 hex. nut, magneto side crankshaft 876070 Reducing socket 1/2 ” to 3/4 “...

  • Page 207: Service Products

    BRP-Rotax MAINTENANCE MANUAL HEAVY SERVICE PRODUCTS Description Part number LOCTITE ANTI SEIZE 297434 LOCTITE 7063 898450 LOCTITE 603 899789 n.a. Abrasive pad Effectivity: 912 i Series 72–20–00 Rev. 0 Page 3 Edition 2 / June 01 2024...
  • Page 208 BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 9.2 72–20–00 Effectivity: 912 i Series Rev. 0 Page 4 Edition 2 / June 01 2024...

  • Page 209: General Note

    BRP-Rotax MAINTENANCE MANUAL HEAVY GENERAL NOTE This section only describes work relating directly to repairing the engine block and its assemblies. Note the cross-references to maintenance work and work on other assemblies which is necessary when work- ing on the engine block.

  • Page 210: Removal

    BRP-Rotax MAINTENANCE MANUAL HEAVY REMOVAL SPRAG CLUTCH HOUSING – REMOVAL Before the sprag clutch is removed, the work de- NOTE scribed below must be carried out to identify any fur- The fly wheel assy. does not have to be disas- ther faults in the engine block and rectify them as sembled for changing the sprag clutch.
  • Page 211 BRP-Rotax MAINTENANCE MANUAL HEAVY NOTE When the crankshaft plug screw M22x1,5 is re- moved, the protection mushroom with part no. 877419 must be used. Figure 9.4 Hex. collar nut Sprag clutch housing M32x1.5 Free wheel gear Step Procedure Figure 9.6: TYPICAL...
  • Page 212 BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 9.7 Sprag clutch housing Puller part no. 877375 Step Procedure Remove the woodruff key from the crankshaft. Figure 9.8 Woodruff key Free wheel gear 72–20–00 Effectivity: 912 i Series Rev. 0 Page 8 Edition 2 / June 01 2024...

  • Page 213: Disassembly

    BRP-Rotax MAINTENANCE MANUAL HEAVY DISASSEMBLY DISASSEMBLING THE SPRAG CLUTCH HOUSING The sprag clutch housing should be disassembled on a clean surface. There must be enough space to lay out the removed parts to ensure that all the parts can be laid out and allocated according to their instal- lation position.

  • Page 214: Inspection

    BRP-Rotax MAINTENANCE MANUAL HEAVY INSPECTION NOTICE SPRAG CLUTCH HOUSING SINGLE If the oil passage is clogged, the generator PARTS — INSPECTION coils are no longer cooled sufficiently. Preparation Clean all parts carefully. See current Maintenance Manual Line (MML) for the respective engine type.

  • Page 215: Sprag Clutch - Inspection

    BRP-Rotax MAINTENANCE MANUAL HEAVY SPRAG CLUTCH – INSPECTION Procedure Step Check whether oil sludge has accumu- lated in the sprag clutch and in the spear body. The spear body of the sprag clutch must be freely movable and may not be damaged.

  • Page 216: Assembly

    BRP-Rotax MAINTENANCE MANUAL HEAVY ASSEMBLY ASSEMBLY OF THE SPRAG CLUTCH HOUSING Step Procedure Clean the taper surface of the sprag clutch housing with a cloth. Apply LOCTITE ANTI SEIZE to the spear body. Figure 9.17 Sprag clutch Seeger ring Circlip Figure 9.16...

  • Page 217: Installation

    BRP-Rotax MAINTENANCE MANUAL HEAVY INSTALLATION NOTICE Preparation Bearing bushing and the free wheel gear may stick to the crankshaft and the sprag clutch Lock crankshaft. may be abraded. See current Maintenance Manual Line Approx. 2 to 3 mm on the underside of the sprag (MML) for the respective engine type.

  • Page 218: Measuring The Axial Clearance Of The Free Wheel Gear

    BRP-Rotax MAINTENANCE MANUAL HEAVY Step Procedure NOTICE Lubricate the idle gear shaft and bore of Check that the passage and oil duct of the the starter intermediate gear with LOC- crankcase are not blocked. TITE ANTI SEIZE. If the oil passage is blocked, the generator coils Install the starter idle gear.

  • Page 219: Wear Limits

    BRP-Rotax MAINTENANCE MANUAL HEAVY WEAR LIMITS Figure 9.23: Free wheel gear, TYPICAL Description Reading new Wear limit Code Readings max. min. 100 % 50 % Axial ES10 0.5 mm 1.1 mm 0.2 mm 0.4 mm actual clearance 0.02 in 0.04 in 0.01 in...

  • Page 220: Finishing Work

    BRP-Rotax MAINTENANCE MANUAL HEAVY FINISHING WORK • Install the ignition housing and fly wheel. See also Chapter 24-20-20 section Internal generator. • Install the electric starter. See Chapter 80-00-00 section Electric starter — installation • Install coolant hoses from cylinder head, water in- let elbow and water pump housing.
  • Page 221 BRP-Rotax MAINTENANCE MANUAL HEAVY Chapter: 72–30–00 CYLINDER HEAD TOPICS IN THIS CHAPTER Special tools............................4 Service products .............................5 System description ..........................6 Safety instruction...........................6 Maintenance ............................6 REMOVAL..............................7 Surrounding assemblies – removal ......................7 Cylinder head — removal........................9 Disassembly............................11 Cylinder head............................11 Rocker arm — removal ........................11 Valve —...
  • Page 222 BRP-Rotax MAINTENANCE MANUAL HEAVY Cylinder head — tightening torque procedure ..................33 Valve cover installation ........................35 Finishing work .............................35 72–30–00 Effectivity: 912 i Series Rev. 0 Page 2 Edition 2 / June 01 2024...
  • Page 223 BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 10.1: Location on the engine Effectivity: 912 i Series 72–30–00 Rev. 0 Page 3 Edition 2 / June 01 2024...

  • Page 224: Special Tools

    BRP-Rotax MAINTENANCE MANUAL HEAVY SPECIAL TOOLS Description Part number Cylinder aligning tool 877263 n.a. Measuring fixture (valve spring inspection) Spring clamp pliers 877840 Valve spring mounting device 877380 876130 Socket wrench 19x12.5 Torx T30 ball-head insert 876180 n.a. Collet Figure 10.2: Special tools 72–30–00...

  • Page 225: Service Products

    BRP-Rotax MAINTENANCE MANUAL HEAVY SERVICE PRODUCTS Description Part number LOCTITE 648 899788 LOCTITE 243 897651 899796 LOCTITE 577 LOCTITE ANTI SEIZE 8151 297434 n.a. Engine oil Figure 10.3: Cylinder head Effectivity: 912 i Series 72–30–00 Rev. 0 Page 5 Edition 2 / June 01 2024...

  • Page 226: System Description

    BRP-Rotax MAINTENANCE MANUAL HEAVY SYSTEM DESCRIPTION The engine type 912 i Series has 4 liquid-cooled cyl- inder heads. SAFETY INSTRUCTION m WARNING Danger of severe burns and scalds! Always allow the engine to cool down to ambient temperature before starting any work.

  • Page 227: Removal

    BRP-Rotax MAINTENANCE MANUAL HEAVY REMOVAL Preparation Before the cylinder head is removed, the work de- scribed below must be carried out to identify any fur- ther faults in the cylinder head and rectify them as part of repair work. NOTICE...
  • Page 228 BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 10.5 Figure 10.7 Coolant temperature Spring type hose clip Hex./torx collar screw Coolant elbow sensor Spark plug connector Isolating flange Coolant hose Step Procedure Step Procedure Release the attachment of the airbox to Loosen 2 Allen screws M6x20 along with the ignition housing.

  • Page 229: Cylinder Head - Removal

    BRP-Rotax MAINTENANCE MANUAL HEAVY NOTICE Do not lose the O-rings! Step Procedure Loosen 2 collar nuts and 2 collar cap nuts diagonally. Figure 10.8 Washer 6.4 Allen screw M6x20 Elbow flange Coolant elbow CYLINDER HEAD — REMOVAL Step Procedure Loosen the Allen screw with washer.
  • Page 230 BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 10.11 Cylinder head assy. Push-rod assy. O-ring Oil return tubes Step Procedure Hold the oil-filled push-rods closed with a finger, remove them and put them down with the corresponding cylinder heads to prevent confusion. NOTE Mark the installation position of the push-rod with an appropriate marker.

  • Page 231: Disassembly

    BRP-Rotax MAINTENANCE MANUAL HEAVY DISASSEMBLY VALVE — REMOVAL CYLINDER HEAD NOTICE The cylinder head should be disassembled on a Avoid damage to the stem seal or guide. clean surface. There must be enough space to lay Before taking out the valves, remove any burrs on out the removed parts to ensure that all the parts can the valve stem.

  • Page 232: Coolant Elbow Inlet - Removal

    BRP-Rotax MAINTENANCE MANUAL HEAVY COOLANT ELBOW INLET — REMOVAL NOTICE Step Procedure If there are leaks, the corresponding oil return Heat the coolant elbow with a hot air gun tubes must be replaced. to approx. 100 °C to 120 °C (212 °F to 248 °F).
  • Page 233 BRP-Rotax MAINTENANCE MANUAL HEAVY Step Procedure Loosen 2 Allen screws with washer. NOTE Remove the connector brackets on cylinder 3/4. Remove the elbow flange and O-ring. NOTE If more than one coolant elbow outlet are re- moved, they must be numbered.

  • Page 234: Inspection

    BRP-Rotax MAINTENANCE MANUAL HEAVY INSPECTION CYLINDER HEAD ASSY. — INSPECTION CYLINDER HEAD Step Procedure SINGLE PARTS - INSPECTION Inspect the cone of the exhaust manifold. Indentations and scratches no greater Preparation than 0.2 mm (0.0079 in.) are permissible. Bumps no greater than 0.1 mm (0.0039 Clean all parts carefully.

  • Page 235: Hardness Test Method

    BRP-Rotax MAINTENANCE MANUAL HEAVY NOTICE NOTICE Cracks in the cylinder head are not permissi- The results of the hardness test must be noted ble! If in doubt, inspect the affected parts for in Chapter 72-30-00, subsection: Wear limits. cracks. Procedure Step Check the spark plug bore.

  • Page 236: Valve - Inspection

    BRP-Rotax MAINTENANCE MANUAL HEAVY VALVE - INSPECTION NOTICE Replace the valve if the valve stem is out of specification, is damaged or shows traces of wear. Procedure Step Check the valve visually for damage and wear. Determine the valve stem diameter and check the valve disc for wear.

  • Page 237: Valve Seats - Inspection

    BRP-Rotax MAINTENANCE MANUAL HEAVY NOTICE Risk of valve fracture at the weld point. 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.

  • Page 238: Valve Spring - Inspection

    BRP-Rotax MAINTENANCE MANUAL HEAVY NOTICE The ring-shaped print on the valve seat faces of the valve seat rings must be continuous and have no breaks. The width of the print corre- sponds to the valve seat width CH02. NOTICE If there are burn marks or distortion, the cylin-...

  • Page 239: Washer - Inspection

    BRP-Rotax MAINTENANCE MANUAL HEAVY Step Procedure Apply a test load (F) and measure the re- maining spring length VT04. Replace valves shorter than the minimum length. Test load for single valve spring configuration Single valve 200 N (45 lbf) spring...

  • Page 240: Rocker Arm And Rocker Arm Shaft - Inspection

    BRP-Rotax MAINTENANCE MANUAL HEAVY Step Procedure Check the surface of the rocker arm shaft and the inner diameter of the rocker arm bushing for traces of wear. Check the valve support surface and ball joint of the rocker arm. Check oil bores in the rocker arm for free passage.

  • Page 241: Rocker Arm Bushing - Inspection

    BRP-Rotax MAINTENANCE MANUAL HEAVY PUSH ROD – INSPECTION NOTICE Excessive engine speed can cause bending of the push rods. Step Procedure Clean push rods and carry out a visual inspection. NOTE Make sure that the two ball heads pressed into the rod fit tightly.

  • Page 242: Wear Limits

    BRP-Rotax MAINTENANCE MANUAL HEAVY WEAR LIMITS Figure 10.34: Wear Limits 72–30–00 Effectivity: 912 i Series Rev. 0 Page 22 Edition 2 / June 01 2024...
  • Page 243 BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 10.35: Wear Limits Effectivity: 912 i Series 72–30–00 Rev. 0 Page 23 Edition 2 / June 01 2024...
  • Page 244 BRP-Rotax MAINTENANCE MANUAL HEAVY Description Current measure- Tolerance Tolerance Code Measure- ment value limit limit ments 100 % 50 % Cylinder head Valve Intake CH01 7.01 mm 7.018 mm 7.150 mm 7.084 mm current guide valve 0.2758 in. 0.2763 in.
  • Page 245 BRP-Rotax MAINTENANCE MANUAL HEAVY Description Current measure- Tolerance Tolerance Code Measure- ment value limit limit ments 100 % 50 % Wear on Intake VT03 0.00 mm 0.00 mm 0.2 mm 0.1 mm current Valve valve 0.0000 in. 0.0000 in. 0.0080 in.
  • Page 246 BRP-Rotax MAINTENANCE MANUAL HEAVY Description Current measure- Tolerance Tolerance Code Measure- ment value limit limit ments 100 % 50 % Rocker arm current Diameter Intake VT05 11.983 11.994 11.950 mm 11.967 of Rock- valve 0.4705 in. er arm 0.4718 in.

  • Page 247: Assembly

    BRP-Rotax MAINTENANCE MANUAL HEAVY ASSEMBLY NOTE CYLINDER HEAD — ASSEMBLY To prevent leakage between oil return tube and cylinder head, roughen the contact surfaces be- Preparation fore lubrication with LOCTITE 648. • Clean all parts carefully. COOLANT ELBOW INLET –...

  • Page 248: Coolant Elbow Outlet - Assembly

    BRP-Rotax MAINTENANCE MANUAL HEAVY NOTE Remove excess LOCTITE. Figure 10.38 COOLANT ELBOW — INSTALLATION Step Procedure Install a new O-ring 19x2 in the cylinder head. Figure 10.37 Fasten the coolant elbow with 2 Allen screws M6x20 and washers 6.4. Tighten- COOLANT ELBOW OUTLET —...

  • Page 249: Valve Installation

    BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 10.39 Allen screws M6x20 Washers 6.4 Elbow flange O-ring 19x2 Figure 10.40 Connector brackets Washer 16/27.9/1 Intake valve VALVE INSTALLATION Valve spring retainer Valve stem seal NOTICE Step Procedure Risk of engine damage if damaged parts are...

  • Page 250: Rocker Arm - Installation

    BRP-Rotax MAINTENANCE MANUAL HEAVY ROCKER ARM — INSTALLATION Step Procedure Compress valve springs with the mount- NOTICE ing device part no. 877380 and collet. Do not use force! The rocker arm bearing is Insert the valve cotters and de-tension slide fit.

  • Page 251: Installation

    BRP-Rotax MAINTENANCE MANUAL HEAVY INSTALLATION CYLINDER HEAD – INSTALLATION Preparation • Clean all parts carefully. • Lightly grease or lubricate O-rings and gaskets. • New studs must be installed, see Chapter 72-30- 10, section Studs – installation NOTICE Studs (expansion screws) may only be used once.

  • Page 252: Cylinder Head (Single) Repaired Per Engine Side

    BRP-Rotax MAINTENANCE MANUAL HEAVY Step Procedure Lubricate the contact area for the collar cap nuts M8 with grease. NOTE No grease for collar nuts M8 contact areas! Hand-tighten 2 M8 collar cap nuts M8 and 2 collar nuts M8 diagonally (maxi- mum 5 Nm/44 in.lb), until cylinder head...

  • Page 253: Cylinder Heads (Both) Repaired Per Engine Side

    BRP-Rotax MAINTENANCE MANUAL HEAVY Step Procedure Clean and degrease all threads of studs. NOTE Collar cap nuts M8 and collar nuts M8 also must be clean and free from residues. Squeezes the cylinder head and the cylin- der together by hand and push towards crankcase.
  • Page 254 BRP-Rotax MAINTENANCE MANUAL HEAVY Step Procedure Step Procedure Attach the cylinder aligning tool part no. See Fig. “screw diagram”. Tighten the 877262 to the intake flange of the cylinder nuts in torque sequence following these heads with 4 Allen screws M6x25 and steps: tighten to 10 Nm (89 in.

  • Page 255: Valve Cover Installation

    BRP-Rotax MAINTENANCE MANUAL HEAVY VALVE COVER INSTALLATION NOTICE There must be a minimum gap of 0.2 mm (0.008 in.) between the valve covers on the out- er contour. The valve covers must not touch each other! NOTICE Ensure the valve cover screw is the correct length! Look out for damaged threads.
  • Page 256 BRP-Rotax MAINTENANCE MANUAL HEAVY Fill with operating fluids or check filling levels. See current Maintenance Manual Line (MML) for the respective engine type, Chapter 12-10-00 section Adding operat- ing fluids. Flush the engine cooling system. See current Maintenance Manual Line...
  • Page 257 BRP-Rotax MAINTENANCE MANUAL HEAVY Chapter: 72–30–10 DISPLACEMENT PARTS TOPICS IN THIS CHAPTER Special tools............................3 Service Products ...........................3 System description ..........................4 Safety instruction...........................4 Maintenance ............................4 Removal ..............................5 Cylinder and piston — removal .......................5 Hydraulic valve tappet – removal ......................6 Inspection ...............................8 Displacement parts —...
  • Page 258 BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 11.1 72–30–10 Effectivity: 912 i Series Rev. 0 Page 2 Edition 2 / June 01 2024...

  • Page 259: Special Tools

    BRP-Rotax MAINTENANCE MANUAL HEAVY SPECIAL TOOLS Description Part number Piston pin extractor assy. 877091 Piston ring spanner, 84 mm 876967 Monohook circlip remover 976380 Installation tool assy. 877802 Figure 11.2: Special tools SERVICE PRODUCTS Description Part number 297434 LOCTITE ANTI SEIZE n.a.

  • Page 260: System Description

    BRP-Rotax MAINTENANCE MANUAL HEAVY SYSTEM DESCRIPTION In the 912 i Series engine, 4 cylinders with "GILNI- SIL"- coated running surfaces are used. The pistons are light alloy full skirt pistons. The piston pin is ax- ially offset by 1 mm (0.03937 in.) with respect to the piston skirt, this is to minimize rocking of the piston.

  • Page 261: Removal

    BRP-Rotax MAINTENANCE MANUAL HEAVY REMOVAL NOTICE Preparation Pistons and piston rings can be damaged. Support pistons by hand! • Remove the cylinder head. See Chapter 72-30-00 of this Manual. Step Procedure CYLINDER AND PISTON — REMOVAL Support the piston by hand and carefully remove the cylinder along with the O-ring.

  • Page 262: Hydraulic Valve Tappet - Removal

    BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 11.5: TYPICAL Figure 11.4: TYPICAL Piston pin extractor Monohook circlip Pistons Extractor spindle part no. 877091 Monohook circlip re- Extracting nut M6 part mover part no. Pistons no. 877155 976380 Step Procedure NOTE Loosen the nut and remove the piston pin Piston pin extractor assy.
  • Page 263 BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 11.6 Mono hook circlip re- Hydraulic valve tappet mover part no. 976380 Effectivity: 912 i Series 72–30–10 Rev. 0 Page 7 Edition 2 / June 01 2024...

  • Page 264: Inspection

    BRP-Rotax MAINTENANCE MANUAL HEAVY INSPECTION Step Procedure DISPLACEMENT PARTS — INSPECTION Check the groove for the piston pin circlip. Carefully remove any burrs. Preparation NOTE Clean all parts carefully. See current Maintenance Manual Line If the groove is excessively worn (>0.3 mm (MML) for the respective engine type, (0.0118 in.), more than the retaining ring), the...

  • Page 265: Piston Rings - Inspection

    BRP-Rotax MAINTENANCE MANUAL HEAVY NOTE NOTE If the determined installation clearance is great- To determine the piston ring joint clearance, re- er than the permissible installation clearance, move the piston rings with piston ring pliers, the piston and/or cylinder must be replaced.

  • Page 266: Piston Pin - Inspection

    BRP-Rotax MAINTENANCE MANUAL HEAVY PISTON PIN — INSPECTION Step Procedure Clean the cooling fins of the cylinder and NOTICE remove carbon residues in the upper re- gion of the cylinder bore. The monohook circlips for the piston pin must only be used once and must therefore be Clean and check the sealing surfaces on replaced.

  • Page 267: Hardness Test Method

    BRP-Rotax MAINTENANCE MANUAL HEAVY NOTE NOTE As long as the min. clearance is achieved, Cylin- The hydraulic valve tappet rotates during opera- der B with red piston and/or Cylinder A with tion, so there is a uniform, rotational symmetri- green piston can be paired.

  • Page 268: Wear Limits

    BRP-Rotax MAINTENANCE MANUAL HEAVY WEAR LIMITS 12 mm / 0.473 in. 09712 Figure 11.15 72–30–10 Effectivity: 912 i Series Rev. 0 Page 12 Edition 2 / June 01 2024...
  • Page 269 BRP-Rotax MAINTENANCE MANUAL HEAVY PI04 / PI05 / PI06 PI07 / PI08 / PI09 15mm / 0.59in. 40mm / 1.57in. 76mm / 2.99in. 09713 Figure 11.16 Effectivity: 912 i Series 72–30–10 Rev. 0 Page 13 Edition 2 / June 01 2024...
  • Page 270 BRP-Rotax MAINTENANCE MANUAL HEAVY Description Reading new Wear Wear Code Readings limit limit 100 % 50 % Piston Cyl. Cyl. Cyl. Cyl. Piston A PI01 83.988 84.002 83.980 83.939 actual 84 mm / 3.3 in. 3.3066 in. 3.3072 3.3027 3.3047...
  • Page 271 BRP-Rotax MAINTENANCE MANUAL HEAVY Description Reading new Wear Wear Code Readings limit limit 100 % 50 % Piston ring groove PI05 0.03 mm 0.07 mm 0.10 mm 0.085 actual clearance 0.001 in. 0.003 in. 0.004 in. compression ring 0.0033 newed...
  • Page 272 BRP-Rotax MAINTENANCE MANUAL HEAVY Description Reading new Wear Wear Code Readings limit limit 100 % 50 % Cylinder Cyl. Cyl. Cyl. Cyl. Cylinder CY01 84.000 84.012 84.080 84.080 actual bore A 84 mm / 3.3 3.3071 in. 3.3075 3.3075 3.3102...
  • Page 273 BRP-Rotax MAINTENANCE MANUAL HEAVY Description Reading new Wear Wear Code Readings limit limit 100 % 50 % actual NOTE Surface cleaning newed of the sealing surfaces of cylin- der and cylinder head with abra- sive paste is allowed. Hardness CY04...

  • Page 274: Installation

    BRP-Rotax MAINTENANCE MANUAL HEAVY INSTALLATION CYLINDER AND PISTON — INSTALLATION Preparation • Clean all parts carefully. HYDRAULIC VALVE TAPPET – INSTALLATION NOTICE If a hydraulic valve tappet has to be replaced, it must be ensured that a hydraulic valve tappet Figure 11.17...
  • Page 275 BRP-Rotax MAINTENANCE MANUAL HEAVY Step Procedure Step Procedure Install the piston in accordance with the Push the piston pin to one side in the pis- following figures. ton, insert the extractor spindle and mount the extracting nut part no. 877155.
  • Page 276 BRP-Rotax MAINTENANCE MANUAL HEAVY NOTICE Always use new monohook circlips.Circlips which are used or have already been installed have insufficient tangential tension, can twist and consequently abrade the groove in the piston. NOTICE The position of the monohook circlip is de- fined by the recess in the piston.

  • Page 277: Studs - Installation

    BRP-Rotax MAINTENANCE MANUAL HEAVY STUDS – INSTALLATION m WARNING NOTICE Wear eye protection. The monohook circlip is under tension! Studs (expansion screws) may only be used once. NOTICE Step Procedure When installing the monohook circlip, hold the Install 2 new studs M8x200 and 2 new piston firmly with your hand to avoid damag- studs M8x186.

  • Page 278: Cylinder Installation

    BRP-Rotax MAINTENANCE MANUAL HEAVY CYLINDER INSTALLATION NOTICE NOTICE The ring gap should never come to lie in the re- gion of the piston pin eye. The suitable piston ring spanner part no. 876967 must be used to avoid ring breakages.

  • Page 279: Fuel System

    BRP-Rotax MAINTENANCE MANUAL HEAVY Chapter: 73–00–00 FUEL SYSTEM TOPICS IN THIS CHAPTER System description ..........................3 ECU ..............................3 Fuel filter...............................3 Safety instruction...........................3 Effectivity: 912 i Series 73–00–00 Rev. 0 Page 1 Edition 2 / June 01 2024...
  • Page 280 BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 12.1: Fuel system 73–00–00 Effectivity: 912 i Series Rev. 0 Page 2 Edition 2 / June 01 2024...

  • Page 281: System Description

    BRP-Rotax MAINTENANCE MANUAL HEAVY SYSTEM DESCRIPTION ENVIRONMENTAL NOTE The fuel passes from the tanks via the water trap to Please observe the disposal regulations appli- the series-connected electric fuel pumps, through cable in your area. fine filter from there to the fuel rails, the injection valves and the fuel pressure regulator.
  • Page 282 BRP-Rotax MAINTENANCE MANUAL HEAVY INTENTIONALLY LEFT BLANK Page 4 Effectivity: 912 i Series Edition 2 / June 01 2024 Rev. 0...
  • Page 283 BRP-Rotax MAINTENANCE MANUAL HEAVY Chapter: 73–10–00 FUEL SYSTEM AND DISTRIBUTION TOPICS IN THIS CHAPTER Special tools............................3 Service products .............................4 System description ..........................7 Fuel pump module..........................7 Fuel distribution.............................7 Safety instruction...........................8 Maintenance ............................8 Removal ..............................9 Fuel pressure regulator – disassembly ....................9 Fuel pressure regulator assy. — removal....................10 Fuel line assy.
  • Page 284 BRP-Rotax MAINTENANCE MANUAL HEAVY Throttle body assy. — installation......................40 Finishing work .............................41 Figure 13.1: Fuel distribution Fuel pump assy. Fuel line assy. Injectors Fuel rail 1/3 Fuel pressure regulator assy. Throttle body Airbox Intake manifold 73–10–00 Effectivity: 912 i Series Rev.

  • Page 285: Special Tools

    BRP-Rotax MAINTENANCE MANUAL HEAVY SPECIAL TOOLS Description Part number n.a. Snap ring pliers 889537 KNIPEX 1099 pliers (or similar OETIKER pliers) 876180 Socket driver T30 Socket wrench 21 876075 Figure 13.2: Special tools Effectivity: 912 i Series 73–10–00 Rev. 0...

  • Page 286: Service Products

    BRP-Rotax MAINTENANCE MANUAL HEAVY SERVICE PRODUCTS Description Part number LITHIUM BASE GREASE 897330 LOCTITE 243 897651 LOCTITE 648 899788 73–10–00 Effectivity: 912 i Series Rev. 0 Page 4 Edition 2 / June 01 2024...
  • Page 287 BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 13.3: Fuel distribution Effectivity: 912 i Series 73–10–00 Rev. 0 Page 5 Edition 2 / June 01 2024...
  • Page 288 BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 13.4 73–10–00 Effectivity: 912 i Series Rev. 0 Page 6 Edition 2 / June 01 2024...

  • Page 289: System Description

    BRP-Rotax MAINTENANCE MANUAL HEAVY SYSTEM DESCRIPTION valves and can be reproduced using the activation time in all operating conditions. Therefore, the same FUEL PUMP MODULE amount of fuel is injected per unit time at all pressure ratios. It is essentially a bypass valve, which opens a...

  • Page 290: Safety Instruction

    BRP-Rotax MAINTENANCE MANUAL HEAVY Fuel lines. Follow the instructions of the aircraft manufacturer. Bubble trap. Follow the instructions of the aircraft manufacturer. Water trap. Follow the instructions of the aircraft manufacturer. Fuel cock. Follow the instructions of the aircraft manufacturer.

  • Page 291: Removal

    BRP-Rotax MAINTENANCE MANUAL HEAVY REMOVAL Remove the feed line to fuel rail 1/3 and the return line to fuel rail 2/4 and fuel pres- Preparation sure regulator. Follow the instructions of Before the fuel distribution system/fuel pump is re- the aircraft manufacturer.

  • Page 292: Fuel Pressure Regulator Assy. - Removal

    BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 13.8 Figure 13.7 Cable ties Hose Retaining ring Fuel pressure regulator Temperature sensor Pressure regulator housing Procedure Step Loosen the banjo bolt with sealing rings. FUEL PRESSURE REGULATOR ASSY. — REMOVAL NOTICE Preparation Do not damage the Exhaust Gas Temperature Carry out functional check (differential sensor (EGT) on cylinder 4.

  • Page 293: Fuel Line Assy. - Removal

    BRP-Rotax MAINTENANCE MANUAL HEAVY Step Procedure Loosen the Allen screws. NOTE 1 M5x35 Allen screw. 1 M5x45 Allen screw. Remove the fuel pressure regulator and housing. Figure 13.11 Fuel rail 1/3 feed line Fuel rail 2/4 outlet line Allen screw with lock washer Figure 13.10: TYPICAL...

  • Page 294: Fuel Rail - Removal

    BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 13.13 Spring washer Allen screw Figure 13.12 Fuel rail cover Banjo bolt Sealing rings Fuel line assy. FUEL RAIL — REMOVAL Preparation NOTICE Do not damage the Exhaust Gas Temperature sensor (EGT). • Remove the fuel line assy. See fuel line assy. –...
  • Page 295 BRP-Rotax MAINTENANCE MANUAL HEAVY Step Procedure Press the metal spring and pull off the connector from the fuel injector. NOTE The cables are labelled INJ_ 1 to INJ_8. Figure 13.15 Allen screw Lock washer Heat shield Step Procedure Remove Allen screw M5x35 from the fuel pressure regulator (only on cylinder 4).

  • Page 296: Fuel Rail - Disassembly

    BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 13.18 Injector connectors Screwdriver Figure 13.19 Step Procedure Allen screw Lock washer Injectors Fuel rail (2/4) Loosen the Allen screws of the fuel rail at- tachment with the lock washers on both Left damper Right damper sides.

  • Page 297: Throttle Body Assy. - Removal

    BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 13.20 Figure 13.21 Right damper Throttle body assy. Left damper Connector Injectors Screw hose clamp Fuel rail Air filter Step Procedure THROTTLE BODY ASSY. — REMOVAL Loosen 3 hex./torx collar screws with the Preparation separating plate.

  • Page 298: Intake Manifold - Removal

    BRP-Rotax MAINTENANCE MANUAL HEAVY NOTICE Do not lose the rubber ring and ensure that it does not remain in the airbox. Step Procedure Remove the throttle body and the rubber ring. Figure 13.24 1-ear clamps Intake manifolds Step Procedure Loosen 4 hex./torx collar screws for at- tachment to the cylinder heads 2/4.
  • Page 299 BRP-Rotax MAINTENANCE MANUAL HEAVY NOTICE NOTICE Screws cannot be completely unscrewed. To Close the intake duct immediately so that no remove the screws, the intake manifold must debris particles can get into the combustion be lifted after loosening all 4 hex./torx collar chamber! screws.

  • Page 300: Airbox - Removal

    BRP-Rotax MAINTENANCE MANUAL HEAVY AIRBOX — REMOVAL NOTE Preparation The Manifold Air Pressure Sensors (MAPS) and Manifold Air Temperature Sensors (MATS) must • Unplug Manifold Air Pressure Sensors (MAPS) only be removed, if absolutely necessary! and Manifold Air Temperature Sensors (MATS).

  • Page 301: Fuel Pump Assy. - Removal

    BRP-Rotax MAINTENANCE MANUAL HEAVY FUEL PUMP ASSY. — REMOVAL Step Procedure NOTE Loosen 4 Allen screws from the cover. Disconnect the fuel pumps (main, aux): The position and type of positioning and attach- ment of the fuel pump depends on the aircraft •...
  • Page 302 BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 13.34 Figure 13.32 Main pump (main) Additional pump (aux) Housing Hex. nuts Connector (Fuel Connector (Fuel pump Fuel pump unit pump 1) Figure 13.33 Connector Step Procedure Remove the fuel pump module from the aircraft according to the aircraft manufac- turer's manual.

  • Page 303: Inspection

    BRP-Rotax MAINTENANCE MANUAL HEAVY INSPECTION NOTE If an O-ring is damaged, the entire fuel pressure Preparation regulator must be replaced. O-rings are not available as spare parts. Clean all parts carefully. See current Maintenance Manual Line (MML) of the respective engine type,...

  • Page 304: Pressure Regulator Housing - Inspection

    BRP-Rotax MAINTENANCE MANUAL HEAVY PRESSURE REGULATOR HOUSING — NOTICE INSPECTION The fuel rail must be replaced if damaged! Procedure Step Check the sealing surfaces of the O-rings for striations. Check the recess of the retaining ring for sharp edges and burrs.

  • Page 305: Intake Manifold - Inspection

    BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 13.40 Injector O-rings INTAKE MANIFOLD — INSPECTION Figure 13.41 NOTE Injection valve bore Intake manifold For intake manifold inspection, dye penetrant or Contact faces (double Threaded bores similar method must be used. ignition coil) Step...

  • Page 306: Connecting Socket - Inspection

    BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 13.43 Figure 13.42 Contact face CONNECTING SOCKET — INSPECTION Procedure Step Inspect connecting socket for damage and wear. AIRBOX — INSPECTION Step Procedure Check the airbox for damage and wear. Figure 13.44 Check the support plates for damage.

  • Page 307: Fuel Pump Assy. Single Parts - Check

    BRP-Rotax MAINTENANCE MANUAL HEAVY Step Procedure Step Procedure Check the throttle body for damage and Ensure that the throttle valve and the wear. Bowden cable can move freely. Check the bearing of the throttle shaft for Check that the fastening and securing el- damage.

  • Page 308: Air Filter - Inspection

    BRP-Rotax MAINTENANCE MANUAL HEAVY AIR FILTER — INSPECTION NOTICE Check the air filter according to the aircraft No longitudinal scratches are allowed on the manufacturer's instructions. See also cur- connections! rent Maintenance Manual Line (MML) of the respective engine type, Chapter 12-20- FUEL FILTER —...
  • Page 309 BRP-Rotax MAINTENANCE MANUAL HEAVY ASSEMBLY Figure 13.47: Fuel pump single parts Fuel pump bracket assy. Fuel pump housing Fuel pump cover Hex. nut M6 Heat protection mat Rubber grommet Main and Aux. fuel pump Allen screw M5x12 Effectivity: 912 i Series 73–10–00...
  • Page 310 BRP-Rotax MAINTENANCE MANUAL HEAVY 1-ear clamp Hoses 1-ear clamp Hoses 1-ear clamp Check valves Connection line Suction line Pressure line 73–10–00 Effectivity: 912 i Series Rev. 0 Page 28 Edition 2 / June 01 2024...

  • Page 311: Assembly

    BRP-Rotax MAINTENANCE MANUAL HEAVY FUEL PUMP ASSY. SINGLE PARTS — Step Procedure ASSEMBLY Temporarily position complete fuel pump module assy. (pump bracket assy. pos. 2 NOTICE with fuel pumps pos. 8 etc.) in the fuel pump housing (pos. 1). Always use new parts for assembly. Only use...
  • Page 312 BRP-Rotax MAINTENANCE MANUAL HEAVY Leakage check Step Procedure Mount and crimp 1-ear-clamps (pos. 11, NOTICE 13). Make sure not to mix up IN (-LET and OUT NOTE (-LET) of fuel pump assembly in the following Use e.g. ear clamp pliers KNIPEX tasks.

  • Page 313: Fuel Pump Assy. - Assembly

    BRP-Rotax MAINTENANCE MANUAL HEAVY Step Procedure Connect the wiring harness connector ap- propriately. See Chapter 76-50-00 Wiring harness. Fix the cover with 4 Allen screws M5x12. Tightening torque 6 Nm (53 in. lb.) Install the fuel line assy. NOTE The position and type of positioning and attachment of the fuel pump de- pends on the aircraft type.
  • Page 314 BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 13.52 Fuel pressure Figure 13.53 regulator Retaining ring 36x1.5 Fuel pressure regulator Step Procedure Pressure regulator Install the fuel pressure regulator in the housing pressure regulator housing until it stops. Procedure Step Install the retaining ring 36x1.5 with the sharp edge to the top.

  • Page 315: Airbox - Assembly

    BRP-Rotax MAINTENANCE MANUAL HEAVY AIRBOX — ASSEMBLY NOTICE Step Procedure 1-ear clamps may only be used once! Secure the nipple with LOCTITE 243. Tightening torque 8 Nm (70 in. lb.) Secure the hex./torx.-flange screw M6x12 and with LOCTITE 243. Tightening torque 8 Nm (70 in. lb.) Install connector bracket with 3 hex./torx.-...

  • Page 316: Installation

    BRP-Rotax MAINTENANCE MANUAL HEAVY INSTALLATION NOTE Airbox must be installed. For fuel pump installation see SI-PAC-016. Step Procedure FUEL PUMP – INSTALLATION Place new isolating flange on the cylinder AIRBOX — INSTALLATION heads. NOTE Check the rubber buffer on the ignition housing for damage.

  • Page 317: Fuel Rail - Installation

    BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 13.59 Injector O-rings NOTE When a used injector is reinstalled, new O-rings must be installed. Step Procedure Install dampers and injectors. Figure 13.58: TYPICAL Outer screw-fastening Inner screw-fastening Image Tag Expected within Figure Tag 1-ear clamp Intake manifold FUEL RAIL –...
  • Page 318 BRP-Rotax MAINTENANCE MANUAL HEAVY Step Procedure Fix the fuel rail on the left and right of the intake manifold with Allen screws M5x12 and lock washers A5. Tightening torque 5 Nm (44 in. lb.) Figure 13.62 NOTICE Do not damage the Exhaust Gas Temperature Figure 13.61...

  • Page 319: Fuel Pressure Regulator Assy. - Installation

    BRP-Rotax MAINTENANCE MANUAL HEAVY Step Procedure Install the fuel rail cover with Allen screws M5x12 and spring washers 12x5.2x0.5. Tightening torque 5 Nm (44 in. lb.) Figure 13.63 Allen screw M5x12 Lock washer A5 Heat shield Step Procedure Figure 13.65 Fix the fuel pressure regulator with Allen screw M5x35 (only cylinder 4).
  • Page 320 BRP-Rotax MAINTENANCE MANUAL HEAVY Step Procedure Fix hose 60 (regulator/airbox) with 2 ca- ble ties. Plug in the coolant temperature sensor (CTS), see Chapter 76-70-00 Sensors actuators. Figure 13.66 Allen screw M5x35 Allen screw M5x45 Heat shield Step Procedure Install the banjo bolt M12x1.5x24 with new sealing rings A12x18.

  • Page 321: Fuel Line Assy. - Installation

    BRP-Rotax MAINTENANCE MANUAL HEAVY FUEL LINE ASSY. — INSTALLATION NOTICE Install the fuel line assy. in a tension-free man- ner. If the line is too far away from the fuel rail, the fuel line must be adjusted. The sealing sur- faces must be parallel.To be sure: The banjo...

  • Page 322: Throttle Body Assy Installation

    BRP-Rotax MAINTENANCE MANUAL HEAVY THROTTLE BODY ASSY. — INSTALLATION NOTE When the throttle body is installed, a new rubber gasket ring must be used! Procedure Step Install the rubber gasket ring. NOTE The rubber gasket ring is installed dry! Figure 13.72 Hex./torx collar...

  • Page 323: Finishing Work

    BRP-Rotax MAINTENANCE MANUAL HEAVY Fill with operating fluids or check filling levels. See current Maintenance Manual Line (MML) for the respective engine type, Chapter 12-10-00 section Adding operat- ing fluids. Carry out an engine test run. See current Maintenance Manual Line...
  • Page 324 BRP-Rotax MAINTENANCE MANUAL HEAVY INTENTIONALLY LEFT BLANK Page 42 Effectivity: 912 i Series Edition 2 / June 01 2024 Rev. 0...

  • Page 325: Ignition Unit

    BRP-Rotax MAINTENANCE MANUAL HEAVY Chapter: 74–00–00 IGNITION UNIT TOPICS IN THIS CHAPTER System description ..........................4 Firing order ............................4 Internal generators A and B........................4 Safety instruction...........................4 Connections for display systems......................4 Knock sensor ............................4 Effectivity: 912 i Series 74–00–00 Rev. 0 Page 1...
  • Page 326 BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 14.1: Ignition unit Spark plug connector Double ignition coil Engine control unit (ECU) Fuse box assy. Connector generator A Connector generator B Crankshaft position sensor (CPS 1/2) Generator A and B 74–00–00 Effectivity: 912 i Series Rev.
  • Page 327 BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 14.2: Layout plan allocation (cylinder/LANE) Effectivity: 912 i Series 74–00–00 Rev. 0 Page 3 Edition 2 / June 01 2024...

  • Page 328: System Description

    BRP-Rotax MAINTENANCE MANUAL HEAVY SYSTEM DESCRIPTION SAFETY INSTRUCTION The ignition unit operates with four double ignition m WARNING coils with double ignition. If the LANE selector switchs are both ON, the active LANE controls all Follow the general safety instructions during...
  • Page 329 BRP-Rotax MAINTENANCE MANUAL HEAVY Chapter: 74–20–00 DISTRIBUTION TOPICS IN THIS CHAPTER Service products .............................3 System description ..........................4 Internal Generators..........................4 Double ignition coils..........................4 Ignition cable assy..........................4 Spark plugs............................4 Wiring harness ............................5 Fuse box...............................5 Crankshaft position sensor (CPS) ......................5 Safety information ..........................5 Removal ..............................6...
  • Page 330 BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 15.1: Location on the engine 74–20–00 Effectivity: 912 i Series Rev. 0 Page 2 Edition 2 / June 01 2024...

  • Page 331: Service Products

    BRP-Rotax MAINTENANCE MANUAL HEAVY SERVICE PRODUCTS Description Part number Silicon heat compound WACKER P12 897186 Figure 15.2: Double ignition coils with blade receptacle (male) connectors Effectivity: 912 i Series 74–20–00 Rev. 0 Page 3 Edition 2 / June 01 2024...

  • Page 332: System Description

    BRP-Rotax MAINTENANCE MANUAL HEAVY SYSTEM DESCRIPTION map to adapt to the different operating states, taking into account the signals of the knock sensor. INTERNAL GENERATORS See Chapter 24-20-00 section Internal generator. DOUBLE IGNITION COILS The four double ignition coils are fastened to the in- take manifolds.

  • Page 333: Wiring Harness

    BRP-Rotax MAINTENANCE MANUAL HEAVY The connecting bolt for the high-voltage ignition ca- bles complies with ISO/DIN standard guidelines. WIRING HARNESS All the electrical components necessary for the en- gine are connected to the wiring harness. See 76-50- 00 Wiring harness.

  • Page 334: Removal

    BRP-Rotax MAINTENANCE MANUAL HEAVY REMOVAL NOTE The rubber seal may need to be pulled back off Preparation the coil in order to unscrew the cable. • Switch the ignition off Engine cleaning. See current Maintenance Manual Line (MML) for the respective engine type.

  • Page 335: Double Ignition Coil - Removal

    BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 15.5: Screwed version (most common) Figure 15.7: TYPICAL Ignition coil connectors Cable ties Step Procedure Remove the cable clamps from the wiring harness. Figure 15.6: Plugged version (uncommon) Ignition coils Cable ties Spark plug connector Ignition cable assy.
  • Page 336 BRP-Rotax MAINTENANCE MANUAL HEAVY Step Procedure Carefully pull EGT 1 and EGT 2 (cylinders 1 and 2) out of the connector plate. Press the metal spring and pull off the connector to the Exhaust Gas Tempera- ture Sensor (EGT). See also...

  • Page 337: Spark Plug - Removal

    BRP-Rotax MAINTENANCE MANUAL HEAVY NOTE Step Procedure The red cable is positive (+), the red cable with Unplug the connectors to the double igni- the black dash is negative (-). Double ignition tion coils. 76-50-00 Wiring harness. coils are labeled + and -! Remove the double ignition coils.

  • Page 338: Inspection

    BRP-Rotax MAINTENANCE MANUAL HEAVY INSPECTION Components can only be replaced, not repaired. If the ignition spark fails, search systematically for the possible cause of the fault. The B.U.D.S. Aircraft di- agnostic tool can be used for this. DOUBLE IGNITION COIL ASSY. AND IGNITION CABLE ASSY.

  • Page 339: Spark Plug Connector - Inspection

    BRP-Rotax MAINTENANCE MANUAL HEAVY SPARK PLUG CONNECTOR — INSPECTION Carry out resistance test on ignition cable assy. To do this, see Chapter 76-70-00 section Sensors and actuators. Step Procedure Check spark plug connectors for corro- sion and damage. SPARK PLUG — INSPECTION...

  • Page 340: Installation

    BRP-Rotax MAINTENANCE MANUAL HEAVY INSTALLATION KNOCK SENSOR — INSTALLATION Chapter 76-70-00 section Sensors and actua- tors Chapter 76-50-00 section Wiring harness. SPARK PLUG — INSTALLATION See current Maintenance Manual Line (MML) for the respective engine type, Chapter 12–20–00 section Inspection of spark plugs.

  • Page 341: Double Ignition Coil (Screwed Connection) - Installation

    BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 15.20 Figure 15.19: Screwed, common/new version Ignition cable assy. Cable ties 203x7.6 Ignition coils Cable ties 94x2.5 DOUBLE IGNITION COIL (SCREWED Spark plug Ignition cable assy. connectors CONNECTION) — INSTALLATION For double ignition coils with blade receptacle...
  • Page 342 BRP-Rotax MAINTENANCE MANUAL HEAVY Step Procedure Fix the double ignition coils with M5x16 Allen screws with connector brackets and A5 lock washers. Tightening torque 5 Nm (44 in. lb.). Figure 15.21: With blade receptacle (male) connectors Ignition coil connector Double ignition coils (coil 1, coil 2, coil 3, coil For double ignition coils with MCON 1.2 (male)

  • Page 343: Double Ignition Coil (Plugged Connection) - Installation

    BRP-Rotax MAINTENANCE MANUAL HEAVY NOTICE Push on 90° ignition coil connectors should be attached with cable ties to reduce vibration. Pull the cable tie tight so it does not allow movement/chafing. Figure 15.24: TYPICAL EGT connector Connector Step Procedure Press the EGT connector into the connec- tor bracket.
  • Page 344 BRP-Rotax MAINTENANCE MANUAL HEAVY Step Procedure Plug in the connector to the EGT connector. NOTE Compress the connector with the EGT connec- tor so that the spring clip latches in. Figure 15.27 Ignition coil connector Double ignition coils (coil 1, coil 2, coil 3, coil...
  • Page 345 BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 15.30 Figure 15.31 Ignition coil connector Double ignition coils Allen screw M6x14 Lock washer A6 Cable clamp 12/M6 EGT connector NOTICE NOTICE The Allen screw for the cable clamp reaches Push on 90° ignition coil connectors should be the intake duct and is therefore glued in with attached with cable ties to reduce vibration.

  • Page 346: Internal Generator - Installation

    BRP-Rotax MAINTENANCE MANUAL HEAVY INTERNAL GENERATOR — INSTALLATION Chapter 24–20–00 section Internal generator. FINISHING WORK Carry out an engine test run. See current Maintenance Manual Line (MML) for the respective engine type, Chapter 12-20-00 section Planned maintenance. 74–20–00 Effectivity: 912 i Series Rev.
  • Page 347 BRP-Rotax MAINTENANCE MANUAL HEAVY Chapter: 75–00–00 COOLING SYSTEM TOPICS IN THIS CHAPTER Special tools............................3 Service products .............................4 System description ..........................7 Coolant..............................7 Radiator..............................7 Water pump ............................7 Expansion tank .............................7 Overflow bottle ............................7 Safety information ..........................7 Connections for display systems......................7 Coolant Temperature Sensor (CTS) ......................8 Maintenance ............................8...
  • Page 348 BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 16.1: Location on the engine 75–00–00 Effectivity: 912 i Series Rev. 0 Page 2 Edition 2 / June 01 2024...

  • Page 349: Special Tools

    BRP-Rotax MAINTENANCE MANUAL HEAVY SPECIAL TOOLS Description Part number Hose clamp pliers 877840 Impeller wrench assy. 877295 Insertion jig 876510 Insertion jig 877258 Socket driver T30 ball head 876180 Socket 19x12.5 876130 Figure 16.2: Special tools Effectivity: 912 i Series 75–00–00...

  • Page 350: Service Products

    BRP-Rotax MAINTENANCE MANUAL HEAVY SERVICE PRODUCTS Description Part number LOCTITE 243 897651 n.a. Engine oil LOCTITE 577 899796 899789 LOCTITE 603 n.a. LOCTITE 7063 75–00–00 Effectivity: 912 i Series Rev. 0 Page 4 Edition 2 / June 01 2024...
  • Page 351 BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 16.3: Cooling system Effectivity: 912 i Series 75–00–00 Rev. 0 Page 5 Edition 2 / June 01 2024...
  • Page 352 BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 16.4 75–00–00 Effectivity: 912 i Series Rev. 0 Page 6 Edition 2 / June 01 2024...

  • Page 353: System Description

    BRP-Rotax MAINTENANCE MANUAL HEAVY SYSTEM DESCRIPTION SAFETY INFORMATION The engine is cooled by liquid-cooled cylinder heads m WARNING and ram-air-cooled cylinders. The cooling system of the cylinder heads is a closed cooling circuit with an Danger of severe burns and scalds! expansion tank and overflow bottle.

  • Page 354: Coolant Temperature Sensor (Cts)

    BRP-Rotax MAINTENANCE MANUAL HEAVY COOLANT TEMPERATURE SENSOR (CTS) Coolant flows around the temperature sensor, which measures the coolant temperature directly. The temperature sensor is situated in cylinder head MAINTENANCE As well as the maintenance and special checks, see current Maintenance Manual Line (MML) for the respective engine type.

  • Page 355: Removal

    BRP-Rotax MAINTENANCE MANUAL HEAVY REMOVAL SURROUNDING ASSEMBLIES — REMOVAL m WARNING Only necessary for upper coolant system and cooling air baffle. Danger of severe burns and scalds! Always allow the engine to cool down to ambient NOTE temperature before starting any work.
  • Page 356 BRP-Rotax MAINTENANCE MANUAL HEAVY Step Procedure Pull back the airbox including the intake manifolds carefully. Close the intake ducts using a plug (part no. 860397). NOTICE Close the intake duct immediately so that no debris particles can get into the combustion chamber! Figure 16.5...

  • Page 357: Expansion Tank With Upper Form Hoses - Removal

    BRP-Rotax MAINTENANCE MANUAL HEAVY EXPANSION TANK WITH UPPER FORM Cylinder 1/3 TYPICAL HOSES - REMOVAL NOTICE Risk of pressure and scuffing marks! Mark the position of the spring clamps. The spring clamps must be re-installed in the same position, otherwise it may not be possible to install the in- take manifold.

  • Page 358: Cooling Air Baffle - Removal

    BRP-Rotax MAINTENANCE MANUAL HEAVY COOLING AIR BAFFLE - REMOVAL Preparation • See Surrounding assemblies – removal Step Procedure Remove expansion tank with upper form hoses. Lift up and remove cooling air baffle. WATER PUMP HOUSING WITH LOWER FORM HOSES — REMOVAL Preparation Figure 16.9...
  • Page 359 BRP-Rotax MAINTENANCE MANUAL HEAVY Step Procedure Loosen the 2 Allen screws of the water in- let elbow with washers and remove the water inlet elbow with the O-ring. NOTE Mark the position of the water inlet el- bow with a suitable pen (touch-up pen).
  • Page 360 BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 16.13 Impeller Washer 75–00–00 Effectivity: 912 i Series Rev. 0 Page 14 Edition 2 / June 01 2024...

  • Page 361: Disassembly

    BRP-Rotax MAINTENANCE MANUAL HEAVY DISASSEMBLY OIL SEAL AND ROTARY SEAL — REMOVAL IGNITION HOUSING — DISASSEMBLY Preparation NOTICE The oil seal and rotary seal are destroyed by • Remove the ignition housing. See Chapter 24-20- this process and must be replaced.

  • Page 362: Water Pump Housing - Disassembly

    BRP-Rotax MAINTENANCE MANUAL HEAVY Remove the form hoses from the bent Step Procedure socket on the expansion tank with a suit- Mark the position of the bent socket. able tool. Heat the water pump housing to approx. NOTE 100 to 120 °C (212 °F to 248 °F) and un- screw the bent socket.

  • Page 363: Inspection

    BRP-Rotax MAINTENANCE MANUAL HEAVY INSPECTION COOLING SYSTEM SINGLE PARTS — INSPECTION NOTICE Cracks in cooling system components are not permissible! If in doubt, check the affected parts for cracks us- ing the dye penetrant or similar method. NOTICE Form hoses must not be shortened, as this af- fects the position of the expansion tank.

  • Page 364: Water Pump Housing - Inspection

    BRP-Rotax MAINTENANCE MANUAL HEAVY WATER PUMP HOUSING — INSPECTION Procedure Step Check the water pump housing for dam- age, deformation and leaks. Check the inner side for any signs of con- tact with the impeller. Measure the gap between impeller and water housing using a feeler gauge, see section Wear limits (WP02).

  • Page 365: Wear Limits

    BRP-Rotax MAINTENANCE MANUAL HEAVY WEAR LIMITS WP01 WP02 09656 Figure 16.21 Description Reading new Wear limit Readings Code max. min. 100 % 50 % Water pump Reference to flat WP01 8.55 mm 8.85 mm 8.85 mm actual surface 0.3366 in 0.3484 in...

  • Page 366: Assembly

    BRP-Rotax MAINTENANCE MANUAL HEAVY ASSEMBLY NOTE IGNITION HOUSING – ASSEMBLY The spacing WP01 is automatically established with insertion jig part no. 877258. Oil seal – Installation NOTE Step Procedure Ensure that no LOCTITE 603 is in contact with Lubricate the outside of a new oil seal the oil seal.

  • Page 367: Water Pump Housing - Assembly

    BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 16.24: TYPICAL Figure 16.25 Ignition housing Oil seal Impeller Washer 8.2/12.5/1.5 Pump shaft Rotary seal NOTE Insertion jig part no. 877258 Ensure that the impeller runs true. If there is no- ticeable runout, this, and possibly also the pump...

  • Page 368: Form Hose - Installation

    BRP-Rotax MAINTENANCE MANUAL HEAVY FORM HOSE – INSTALLATION NOTICE The push-on length of the expansion tank is 25 mm (0.9843 in.)! NOTICE Hoses must not be shortened! NOTE The hoses are all preformed and cut to length in the factory, and the hose length and push-on length therefore defines the position of the ex- pansion tank.
  • Page 369 BRP-Rotax MAINTENANCE MANUAL HEAVY Step Procedure Install the spring clamp 35 on the form hose radiator outlet. Push on the form hose onto the radiator outlet and align it vertically. NOTE Align the spring clamp 35 vertically too so that the remaining form hoses can be installed.
  • Page 370 BRP-Rotax MAINTENANCE MANUAL HEAVY NOTE Align the spring clamp 25 so that it is 2 mm (0.0787 in.) away from the spring clamp 25 on form hose 3. Procedure Step Push on form hose 1 and align it horizon- tally like form hose 3.
  • Page 371 BRP-Rotax MAINTENANCE MANUAL HEAVY NOTE Form hose 2 is symmetrical. Figure 16.33 Spring clamp 25 Form hose 4 Expansion tank Procedure Step Install the spring clamp 25 on form hose 2 and position it vertically. Push on form hose 2 and align it horizontally.

  • Page 372: Installation

    BRP-Rotax MAINTENANCE MANUAL HEAVY INSTALLATION NOTICE IGNITION HOUSING — INSTALLATION The bottom M6x35 Allen screw extends into Chapter 24–20–00 section Ignition housing – the water chamber and is therefore stainless installation steel and sealed with a new sealing ring. WATER PUMP HOUSING WITH LOWER FORM HOSES —...
  • Page 373 BRP-Rotax MAINTENANCE MANUAL HEAVY NOTICE Ensure that the push-on length is correct! The push-on length onto the bent socket on the water pump housing and cylinder head is 27 mm (1.06 in.) Figure 16.36: TYPICAL Water pump housing Allen screw M6x20 Washer 6.4...

  • Page 374: Cooling Air Baffle - Installation

    BRP-Rotax MAINTENANCE MANUAL HEAVY Step Procedure Install 1 spring clamp 25 each on form ho- ses 1, 2, 3, and 4. Position the expansion tank assy. with the 5 form hoses on the engine. Figure 16.38 Spring clamps 25 Bent sockets Form hoses COOLING AIR BAFFLE –...

  • Page 375: Surrounding Assemblies - Installation

    BRP-Rotax MAINTENANCE MANUAL HEAVY Form hose 3 Form hose 4 Spring clamp SURROUNDING ASSEMBLIES — INSTALLATION Only necessary for upper coolant system and cooling air baffle. Procedure Step Remove plug (part no. 860397) from the intake ducts. Push the airbox including the intake mani- folds onto the engine carefully.

  • Page 376: Finishing Work

    BRP-Rotax MAINTENANCE MANUAL HEAVY Step Procedure Spark plug Water inlet elbow connector Route lower ignition cables and install Allen screw with and connect lower spark plug connectors. lock washer and ca- Coolant outlet See Chapter 74-20-00, section Spark ble clamp plug connector and ignition cable assy.
  • Page 377 BRP-Rotax MAINTENANCE MANUAL HEAVY Carry out an engine test run. See current Maintenance Manual Line (MML) for the respective engine type, Chapter 12-20-00 section Planned maintenance Effectivity: 912 i Series 75–00–00 Rev. 0 Page 31 Edition 2 / June 01 2024...
  • Page 378 BRP-Rotax MAINTENANCE MANUAL HEAVY INTENTIONALLY LEFT BLANK Page 32 Effectivity: 912 i Series Edition 2 / June 01 2024 Rev. 0...

  • Page 379: Engine Control

    BRP-Rotax MAINTENANCE MANUAL HEAVY Chapter: 76–00–00 ENGINE CONTROL TOPICS IN THIS CHAPTER Introduction The Engine Management System (EMS) consists primarily of: • Control unit (Electronic Control Unit = ECU) • ECU signals • EMS power supply • Fuse box • Switches •...
  • Page 380 BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 4.1: Location on the engine 76–00–00 Effectivity: 912 i Series Rev. 0 Page 2 Edition 2 / June 01 2024...
  • Page 381 BRP-Rotax MAINTENANCE MANUAL HEAVY Chapter: 76–10–00 ENGINE CONTROL UNIT (ECU) TOPICS IN THIS CHAPTER Special tools............................2 System description ..........................4 General note ............................4 Safety instruction...........................4 Maintenance ............................4 Technical data ............................5 Removal ..............................7 ECU — removal ............................7 Inspection ...............................8 ECU — inspection ..........................8 Installation...............................9...

  • Page 382: Special Tools

    BRP-Rotax MAINTENANCE MANUAL HEAVY SPECIAL TOOLS Description Part number B.U.D.S SET LEVEL 1 864021 B.U.D.S SET LEVEL 2 864022 864023 B.U.D.S SET LEVEL 3 GOST_A4_first_page_text Service Wiring Harness 864280 n.a. Y-Cable (Sub-D DE9 female on male/male junction) 2) 3) n.a.
  • Page 383 BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 17.2: Control unit (ECU) Effectivity: 912 i Series 76–10–00 Rev. 0 Page 3 Edition 2 / June 01 2024...

  • Page 384: System Description

    BRP-Rotax MAINTENANCE MANUAL HEAVY SYSTEM DESCRIPTION GENERAL NOTE The control unit is the central module in the engine management system. Sensors continuously measure pressure, rotation speed, temperature, load and knock signals and send these measurement values to the ECU. The digital ECU uses these measurement values to...

  • Page 385: Technical Data

    BRP-Rotax MAINTENANCE MANUAL HEAVY TECHNICAL DATA Figure 17.3: ECU Connector socket A1 Connector socket A2 Attachment points Connector socket B Effectivity: 912 i Series 76–10–00 Rev. 0 Page 5 Edition 2 / June 01 2024...
  • Page 386 BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 17.4: Control unit ECU 76–10–00 Effectivity: 912 i Series Rev. 0 Page 6 Edition 2 / June 01 2024...

  • Page 387: Ecu Removal

    BRP-Rotax MAINTENANCE MANUAL HEAVY REMOVAL Preparation Before the ECU is removed, the work and checks de- scribed below must be carried out to identify any mal- functions and rectify them as part of the repair work. • Turn the ignition switch “OFF”...

  • Page 388: Ecu - Inspection

    BRP-Rotax MAINTENANCE MANUAL HEAVY INSPECTION ECU — INSPECTION NOTICE The functional test of the ECU can only be car- ried out with the corresponding software (B.U. D.S. Aircraft), as part of an engine test run (see relevant Maintenance Manual Line 12-20-00) or on an approved test bench.

  • Page 389: Ecu Installation

    BRP-Rotax MAINTENANCE MANUAL HEAVY INSTALLATION Preparation NOTICE The wire connectors of the ECU must not be opened and closed more than 20 times! This must be shown on the device by a clearly visi- ble label with a printed numerical sequence (1- 20) and by documentation conforming to self- monitoring guidelines.

  • Page 390: Ecu - Read Out And Flashing

    BRP-Rotax MAINTENANCE MANUAL HEAVY ECU – READ OUT AND FLASHING Introduction The intention of this procedural instruction is to guide users through the process of identifying the soft- ware- and hardware version of an ECU. Although ECU software changes must be documented within...

  • Page 391: Ecu On Workbench

    BRP-Rotax MAINTENANCE MANUAL HEAVY ECU ON WORKBENCH NOTICE Do not open and close the ECU connectors more than 20 times, otherwise it is required to change the ECU and the wiring harness. If it is possible it is recommended to perform the software loading process as described in Sit- uation 2 to save connection cycles.
  • Page 392 BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 17.11: ECU configuration tab Figure 17.10: B.U.D.S. Aircraft Start Step Procedure Step Procedure Read and note the values of following fields: Wait until the program has been started completely. • Software P/N: This value indicates the current software installed on the ECU.

  • Page 393: Read Out Log Files

    BRP-Rotax MAINTENANCE MANUAL HEAVY READ OUT LOG FILES Step Procedure General Disconnect and re-connect the power To have all information it is recommended to extract supply if B.U.D.S. Aircraft requests to do Lane A and B and also Fault and Data logs. The ex- traction process (read out) may take 10 minutes or more depending on the number of logs.

  • Page 394: Software Update

    BRP-Rotax MAINTENANCE MANUAL HEAVY Step Procedure Check the currently installed ECU Soft- ware version and the set Engine type. NOTE The last three digits of the “Software P/N“ illustrate the currently installed ECU Software version. Figure 17.14 Step Procedure Disconnect the wiring connecting the ECU with the computer.
  • Page 395 BRP-Rotax MAINTENANCE MANUAL HEAVY Step Procedure be done. See following Figure for exam- ple of correct health tab (using service harness only). The Software flashing process itself is now complete. Switch “OFF” the ECU. Remove all wiring connections. Figure 17.16: : TYPICAL...

  • Page 396: Ecu Installed In Aircraft

    BRP-Rotax MAINTENANCE MANUAL HEAVY ECU INSTALLED IN AIRCRAFT The identification of current ECU configuration, read out of logs and the software updating process is the same as on workbench, see previous section. CONNECTION NOTICE The battery must provide constant voltage thru the whole extraction process.
  • Page 397 BRP-Rotax MAINTENANCE MANUAL HEAVY Chapter: 76–20–00 FUSE BOX TOPICS IN THIS CHAPTER System description ..........................3 General note ............................3 Safety instruction...........................3 Maintenance ............................3 Technical data ............................4 Removal ..............................5 Fuse Box — removal ..........................5 Regulator B — removal..........................5 Regulator A — removal..........................8 Installation.............................10...
  • Page 398 BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 18.1 Fuse box assy. Regulator B Regulator A Sealing insert Heat transfer pad Fuses 76–20–00 Effectivity: 912 i Series Rev. 0 Page 2 Edition 2 / June 01 2024...

  • Page 399: System Description

    BRP-Rotax MAINTENANCE MANUAL HEAVY SYSTEM DESCRIPTION NOTE GENERAL NOTE The general safety instructions must be followed during all work on the fuse box! All the components of the voltage supply, e.g. fuses, are included in the power supply unit. MAINTENANCE...
  • Page 400 BRP-Rotax MAINTENANCE MANUAL HEAVY TECHNICAL DATA NOTE Dimensions are the same as with Deutsch connector (regulator B). Figure 18.2: Fuse Box, TYPICAL 76–20–00 Effectivity: 912 i Series Rev. 0 Page 4 Edition 2 / June 01 2024...

  • Page 401: Fuse Box - Removal

    BRP-Rotax MAINTENANCE MANUAL HEAVY REMOVAL Preparation Before the fuse box is removed, the work and checks described below must be carried out to identify any further malfunctions in the engine and rectify them as part of the repair work. • Turn the ignition switch “OFF”...
  • Page 402 BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 18.4: DEUTSCH connector Figure 18.6: TYPICAL Cap nut of the gasket Regulator A Regulator B Regulator B screw connection Cover Plastic washer M4 Allen screws M4 Step Procedure Disconnect the 2 RED/WHITE cable from connection bolt B+. Remove the M5 lock nut with washer.
  • Page 403 BRP-Rotax MAINTENANCE MANUAL HEAVY Step Procedure Remove the regulator B. Remove the 2 M6 lock nut with washer. Wrench size: A/ F 10. NOTE Previous versions of the fuse box may have M4 lock nuts on Regulator B, new versions have M6 lock nuts.

  • Page 404: Regulator A - Removal

    BRP-Rotax MAINTENANCE MANUAL HEAVY NOTE Be careful when handling the dismantled regula- tor. On the back side of the regulator and the regulator plate thermal paste can adhere. REGULATOR A — REMOVAL Step Procedure Loosen the gasket screw connection. Wrench size A/F 25.
  • Page 405 BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 18.14: TYPICAL Figure 18.12: TYPICAL Regulator plate Regulator A Regulator A Regulator B Washer Lock nut M6 Connection bolt regu- Connection bolt regula- lator A tor B Step Procedure Regulator plate Pull the 2 RED-WHITE and the 2 BLACK cables with grommet out of the fuse box.

  • Page 406: Installation

    BRP-Rotax MAINTENANCE MANUAL HEAVY INSTALLATION NOTE If the wire is broken or the connector is defec- tive, the damage can be repaired. The wire must be long enough if the connector is cut off. Repair with the tools described here must comply with the aircraft standard of the respective country.

  • Page 407: Regulator B - Installation

    BRP-Rotax MAINTENANCE MANUAL HEAVY REGULATOR B — INSTALLATION NOTICE NOTICE The regulator must be mounted so that it does not project beyond the regulator plate. The surface on the back of the regulator must be cleaned before applying the heat transfer...
  • Page 408 BRP-Rotax MAINTENANCE MANUAL HEAVY NOTICE When pressing in the gasket screw connec- tion, avoid damaging the connecting thread. Step Procedure Pull all the cables 2 RED/WHITE (mark- ing: B+) and 4 BLACK (marking: B and B- ) into the fuse box. The plastic insert must be pressed completely into the connect- ing thread of sealing union.
  • Page 409 BRP-Rotax MAINTENANCE MANUAL HEAVY NOTICE Note the wire marking and labeling of the con- necting bolts (labeled on the board of the fuse box). All cables must be installed without kinks. NOTICE The ring terminals attached to the connecting ports B-, B and B+ must not touch each other (except those rings which are attached to the same connection bolt).

  • Page 410: Regulator A - Installation

    BRP-Rotax MAINTENANCE MANUAL HEAVY REGULATOR A — INSTALLATION NOTICE NOTICE The ring terminals attached to the connecting ports B-, B and B+ must not touch each other The surface on the back of the regulator must (except those rings which are attached to the be cleaned before applying the heat transfer same connection bolt).
  • Page 411 BRP-Rotax MAINTENANCE MANUAL HEAVY NOTICE The regulator must be mounted so that it does not project beyond the regulator plate. Step Procedure Fasten regulator A on the regulator plate with 2 new lock nuts M6 and washers 6.4. Tightening torque: 6 Nm (53 in. lb).
  • Page 412 BRP-Rotax MAINTENANCE MANUAL HEAVY NOTICE Note the wire marking and labeling of the con- necting bolts (labeled on the board of the fuse box). All cables must be installed without kinks. NOTICE The ring terminals attached to the connecting ports A-, A and A+ must not touch each other (except those rings which are attached to the same connection bolt).
  • Page 413 BRP-Rotax MAINTENANCE MANUAL HEAVY Step Procedure Connect the unlabeled cable ends com- ing out of the fuse box and the regulator (2 pcs. BLACK) with the regulator plate. Positioning of the cables must be as shown in figure connection overview and connection above.

  • Page 414: Cover - Installation

    BRP-Rotax MAINTENANCE MANUAL HEAVY FUSES If a fuse is damaged, it must be replaced by a new one with the same values. m WARNING A fuse with a higher amperage must not be used, as this can lead to severe damage.

  • Page 415: Fuse Box - Installation

    BRP-Rotax MAINTENANCE MANUAL HEAVY NOTICE If a conductive connection (continuity) is present, the installation of the regulator has to be checked. The fuse box must not be installed in an aircraft until the error is fixed and the in- stallation corrected.

  • Page 416: Finishing Work

    BRP-Rotax MAINTENANCE MANUAL HEAVY FINISHING WORK Step Procedure Connect the aircraft wiring harness in ac- • Attach all the necessary fastenings (e.g. cable ties, cordance with the aircraft manufacturer’s holders, clamps etc.) of the wiring harness. specifications. Carry out an engine test run. See Mainte-...
  • Page 417 BRP-Rotax MAINTENANCE MANUAL HEAVY Chapter: 76–50–00 WIRING HARNESS (MAIN STRAND) TOPICS IN THIS CHAPTER Special tools............................4 Service products ...........................4 System description ..........................7 General note ............................7 Safety instruction...........................7 Maintenance ............................7 Removal ..............................8 HIC A and HIC B — disconnection ......................8 Starter relay — disconnection.........................8 Ambient air pressure and temperature sensor —...
  • Page 418 BRP-Rotax MAINTENANCE MANUAL HEAVY HIC A and HIC B — connection ......................24 Finishing work .............................24 76–50–00 Effectivity: 912 i Series Rev. 0 Page 2 Edition 2 / June 01 2024...
  • Page 419 BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 19.1: Location on the engine Effectivity: 912 i Series 76–50–00 Rev. 0 Page 3 Edition 2 / June 01 2024...

  • Page 420: Special Tools

    BRP-Rotax MAINTENANCE MANUAL HEAVY SPECIAL TOOLS Description Part number n.a. Multimeter ECU Adapter 277012 SERVICE PRODUCTS Description Part number LOCTITE 243 897651 n.a. Deoxit contact spray 76–50–00 Effectivity: 912 i Series Rev. 0 Page 4 Edition 2 / June 01 2024...
  • Page 421 BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 19.2: Wiring harness (main strand) ECU LANE A1 connector ECU LANE A2 connector ECU LANE B connector FUSE BOX LANE X2 FUSE BOX LANE X1 AAPTS Sensor connector Starter relay Starter relay Effectivity: 912 i Series 76–50–00...
  • Page 422 BRP-Rotax MAINTENANCE MANUAL HEAVY CPS 1/2 connector OPS connector Knock connector (old version only) OTS connector MAPS connector MATS connector EGT connector CTS connector Injector connector TPS connector Fuel pump connector Connector ignition coil (old version) Connector ignition coil (new version)

  • Page 423: System Description

    BRP-Rotax MAINTENANCE MANUAL HEAVY SYSTEM DESCRIPTION GENERAL NOTE The wiring harness consists essentially of two main parts, one for LANE A and one for LANE B. Both are each connected with connectors to the ECU and to the individual connectors to the sensors and actuators.

  • Page 424: Starter Relay - Disconnection

    BRP-Rotax MAINTENANCE MANUAL HEAVY REMOVAL HIC A AND HIC B — DISCONNECTION Wiring harness designation: Preparation • HIC_A General visual inspection. See current Maintenance Manual Line • HIC_B (MML) for the respective engine type, Chapter 05-00-00 and 12-00-00. Disconnect the HIC_A and HIC_B connec- tors in accordance with the aircraft manu- facturer’s specifications.

  • Page 425: Ambient Air Pressure And Temperature Sensor - Disconnection

    BRP-Rotax MAINTENANCE MANUAL HEAVY AMBIENT AIR PRESSURE AND TEMPERATURE SENSOR — DISCONNECTION Wiring harness designation: • AAPTS Step Procedure Push in the tab on the top of the connec- tor and at the same time pull the connec- tor out of the connection socket.

  • Page 426: Fuel Pump - Disconnection

    BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 19.7 Figure 19.6 Allen screws Fuel inlet NOTE Fuel outlet Round connectors have different index grooves and cannot be mixed up. Step Procedure Unplug the connectors (FUEL PUMP 1, Step Procedure FUEL PUMP 2) from the fuel pumps.
  • Page 427 BRP-Rotax MAINTENANCE MANUAL HEAVY • ECU LANE A2 NOTICE • ECU LANE B Do not pull on the cable! Step Procedure Unplug the ECU connectors (ECU LANE A1, ECU LANE A2 and ECU LANE B). See Chapter Chapter 76-10-00 section Engine Control Unit.
  • Page 428 BRP-Rotax MAINTENANCE MANUAL HEAVY Step Procedure Carefully pull EGT_3 and EGT_4 (cylin- der 3/4) out of the connector bracket. Press the metal spring and pull off the connector to the Exhaust Gas Tempera- ture sensor (EGT) Figure 19.11 Allen screw...

  • Page 429: Oil Temperature Sensor And Oil Pressure Sensor - Disconnection

    BRP-Rotax MAINTENANCE MANUAL HEAVY Step Procedure NOTICE Disconnect the plug connection to the Do not damage the wiring harness. Always cut coolant temperature sensor by lifting the cable ties on the side of the support plate fac- latch and pull off the connector at the ing away from the wiring harness.
  • Page 430 BRP-Rotax MAINTENANCE MANUAL HEAVY NOTICE Do not damage the wiring harness. Always cut cable ties on the side of the support plate facing away from the wiring harness. Step Procedure Remove cable tie. Lift the latch and pull off the connector to the Oil Temperature Sensor (OTS) and Oil Pressure Sensor (OPS).
  • Page 431 BRP-Rotax MAINTENANCE MANUAL HEAVY NOTICE Do not damage the wiring harness. Always cut cable ties on the side of the support plate facing away from the wiring harness. Step Procedure Remove the 2 cable ties and 2 clips. Lift the latch and pull off the connectors to the manifold air pressure sensors (MAPS_1, MAPS_2).
  • Page 432 BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 19.21 Figure 19.20 Manifold Air Tempera- Manifold Air Pressure ture Sensors (MATS_ Cable ties Sensor 1, MATS_2) MANIFOLD AIR TEMPERATURE Step Procedure SENSOR (MATS) — DISCONNECTION Remove the cable ties from the airbox. Wiring harness designation: If necessary, unscrew clamps and re- move it with Allen screws and washers.

  • Page 433: Wiring Harness Removal

    BRP-Rotax MAINTENANCE MANUAL HEAVY WIRING HARNESS REMOVAL • The wiring harness can be removed after all clamps and cable ties are removed and connec- tors disconnected. Effectivity: 912 i Series 76–50–00 Rev. 0 Page 17 Edition 2 / June 01 2024...
  • Page 434 BRP-Rotax MAINTENANCE MANUAL HEAVY INSPECTION NOTICE When work is carried out on the components of the engine management system, there is a risk that these might get damaged. Never put measuring probes in plug connectors or use other "aids" to carry out tests in the plug connectors.

  • Page 435: Installation

    BRP-Rotax MAINTENANCE MANUAL HEAVY INSTALLATION NOTE If necessary, clean the pins of the connector Preparation and coat them as follows: AMP/ECU connector • Check all the wiring harness sections provided. with a thin layer of Deoxit contact spray. All the other connectors with a dielectric sili- cone-based lubricant or an equivalent lubricant.

  • Page 436: Wiring Harness - Installation

    BRP-Rotax MAINTENANCE MANUAL HEAVY WIRING HARNESS — INSTALLATION Wiring harness Figure 19.25 NOTE If the wire is broken or the connector is defective, the damage can be repaired. The cable must be 76–50–00 Effectivity: 912 i Series Rev. 0 Page 20...
  • Page 437 BRP-Rotax MAINTENANCE MANUAL HEAVY long enough if the connector is cut off. Repair with the tools described here must comply with the aircraft standard of the respective country. NOTE New version of wiring harness without KNOCK connector. Part no. of connector set...
  • Page 438 BRP-Rotax MAINTENANCE MANUAL HEAVY NOTE Do not forget to attach the cable ties (strain relief). Figure 19.26 Manifold Air Pressure Manifold Air Tempera- Sensors ture Sensors Clips Cable ties Figure 19.28 Manifold Air Pressure Manifold Air Tempera- Sensors ture Sensors...
  • Page 439 BRP-Rotax MAINTENANCE MANUAL HEAVY DOUBLE IGNITION COIL – CONNECTION NOTE See Chapter 74-20-00, section Double ignition coil The connectors of the sensors are marked with (screwed connection) — installation dots: EXHAUST GAS TEMPERATURE • CPS_1 (marked with 1 dot) SENSOR (EGT) — CONNECTION •...
  • Page 440 BRP-Rotax MAINTENANCE MANUAL HEAVY NOTICE The wire connectors of the ECU must not be opened and closed more than 20 times! This must be shown on the device by a clearly visi- ble label with a printed numerical sequence (1- 20) and by documentation conforming to self- monitoring guidelines.
  • Page 441 BRP-Rotax MAINTENANCE MANUAL HEAVY • Connect the wiring harness to the aircraft frame in Carry out an engine test run. See latest accordance with the aircraft manufacturer's Maintenance Manual Line (MML), Chapter specifications. 12-20-00. Effectivity: 912 i Series 76–50–00 Rev. 0...
  • Page 442 BRP-Rotax MAINTENANCE MANUAL HEAVY INTENTIONALLY LEFT BLANK Page 26 Effectivity: 912 i Series Edition 2 / June 01 2024 Rev. 0...
  • Page 443 BRP-Rotax MAINTENANCE MANUAL HEAVY Chapter: 76–70–00 SENSORS AND ACTUATORS TOPICS IN THIS CHAPTER Special tools............................3 Service products .............................4 System description ..........................7 General note ............................7 Sensors ..............................7 Actuators and indicators.........................7 Safety instruction...........................8 Maintenance ............................8 Removal ..............................9 Manifold air pressure sensor (MAPS_1/MAPS_2) — removal ..............9 Oil pressure sensor (OPS) —...
  • Page 444 BRP-Rotax MAINTENANCE MANUAL HEAVY Installation.............................28 Oil pressure sensor (OPS) — installation....................28 Manifold air pressure sensor (MAPS_1/MAPS_2) — installation .............28 Ambient air pressure and temperature sensor (AAPTS) — installation.............29 Coolant temperature sensor (CTS) — installation...................29 Manifold air temperature sensor (MATS_1/MATS_2) — installation ............30 Oil temperature sensor (OTS) —...
  • Page 445 BRP-Rotax MAINTENANCE MANUAL HEAVY SPECIAL TOOLS Description Part number n.a. Multimeter Non certified part 21 mm socket for MAPS and OPS 876075 Non certified part 19 mm socket for CTS and OTS 876130 Non certified part Figure 20.1: Special tools Effectivity: 912 i Series 76–70–00...

  • Page 446: Service Products

    BRP-Rotax MAINTENANCE MANUAL HEAVY SERVICE PRODUCTS Description Part number LOCTITE 243 897651 LOCTITE ANTI SEIZE 297434 76–70–00 Effectivity: 912 i Series Rev. 0 Page 4 Edition 2 / June 01 2024...
  • Page 447 BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 20.2: Sensors Knock sensor (KNOCK) (only with old Wiring Crankshaft position sensor (CPS 1 + 2) harness) Ambient pressure sensor (AAPTS) Exhaust Gas Temperature sensor (EGT) Coolant Temperature Sensor (CTS) and Oil temper- Throttle position sensor (TPS)
  • Page 448 BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 20.3: Actuators Double ignition coils Fuel injectors 76–70–00 Effectivity: 912 i Series Rev. 0 Page 6 Edition 2 / June 01 2024...

  • Page 449: System Description

    BRP-Rotax MAINTENANCE MANUAL HEAVY SYSTEM DESCRIPTION "Knocking" means uncontrolled combustion in petrol engines, which is caused by auto-ignition of the mix- GENERAL NOTE ture in the combustion chamber. This undesirable combustion results in increased mechanical loads in In order to ensure that the engine is in the desired the engine.

  • Page 450: Maintenance

    BRP-Rotax MAINTENANCE MANUAL HEAVY SAFETY INSTRUCTION m WARNING Danger of injury when removing hose connec- tions, sensors and actuators! Risk of fire due to flammable substances (e.g. fuel). Open flames and smoking in the installation area is not permitted! NOTICE...
  • Page 451 BRP-Rotax MAINTENANCE MANUAL HEAVY REMOVAL Preparation Sensor LANE A Before the sensors and actuators are removed, the LANE A procedures and checks described below must be carried out to identify any further faults in the cylinder head and rectify them as part of repair work.

  • Page 452: Oil Pressure Sensor (Ops) - Removal

    BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 20.5 Figure 20.6 Manifold air pressure sensor (MAPS) Oil pressure sensor Cable ties (OPS) OIL PRESSURE SENSOR (OPS) — Procedure Step REMOVAL Loosen the oil pressure sensor with a 19 NOTE mm socket (part no. 876130) and remove...
  • Page 453 BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 20.8 Figure 20.7 Manifold air tempera- Ambient air pressure Cable ties ture sensors and temperature sen- Connection socket sor (AAPTS) Step Procedure MANIFOLD AIR TEMPERATURE Unscrew the sensor with a 19 mm socket (part no. 876130) and remove it together SENSOR (MATS_1/MATS_2) —...

  • Page 454: Oil Temperature Sensor (Ots) - Removal

    BRP-Rotax MAINTENANCE MANUAL HEAVY EXHAUST GAS TEMPERATURE SENSOR (EGT_1, EGT_2, EGT_3, EGT_4) — REMOVAL Installation position: Exhaust pipes Step Procedure Disconnect the exhaust gas temperature sensor (EGT1/EGT2/ EGT3/EGT/4). See Chapter 76-50-00 section Wiring harness – removal. Figure 20.11 Exhaust Gas Tempera-...
  • Page 455 BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 20.12 Figure 20.13 Oil temperature Coolant temperature Cable ties sensor sensor (CTS) Step Procedure KNOCK SENSOR (KNOCK) — REMOVAL Use a 19 mm socket (part no. 876130) to Preparation remove the oil temperature sensor from the crankcase.
  • Page 456 BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 20.14 Figure 20.16 Connector Connector bracket Knock sensor Hex. screw Cable tie CRANKSHAFT POSITION SENSOR (CPS_1/CPS_2) — REMOVAL NOTE When removing the crankshaft position sensor, oil may leak from the bore. Installation position: Ignition housing NOTICE Do not damage the cables.

  • Page 457: Throttle Potentiometer (Tps) - Removal

    BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 20.17 Figure 20.18 Connector CPS_1 Connector CPS_2 Crankshaft position Crankshaft position sensor CPS_1 sensor CPS_2 Connector bracket Cable ties Cable clamp Washer Step Procedure Allen screw M6x50 Lock washer Remove the Allen screw with washer and Allen screw M6x20 remove the cable clamp.

  • Page 458: Double Ignition Coil - Removal

    BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 20.19 Throttle position sen- Throttle body assy. sor (TPS) FUEL INJECTOR (INJ) — REMOVAL For removal of the fuel injection, see Chapter 73-10- 00, section Fuel rail — removal. DOUBLE IGNITION COIL — REMOVAL For removal of the double ignition coils, see Chapter 74-20-00, section Double ignition coil –...

  • Page 459: Sensors And Actuators

    BRP-Rotax MAINTENANCE MANUAL HEAVY INSPECTION GENERAL RESISTANCE MEASUREMENT SENSORS AND ACTUATORS Before checking the resistance, ensure that there is no voltage present at the component to which the NOTICE ohmmeter is connected. Always pull out the connec- Replace parts in the event of physical damage tors beforehand.

  • Page 460: Resistance Measurement

    BRP-Rotax MAINTENANCE MANUAL HEAVY RESISTANCE MEASUREMENT VOLTAGE MEASUREMENT (TEMPERATURE SENSOR) General note General note NOTICE If resistance values are measured with an ohmmeter, all values are given at a temperature of approx. 20 ° Voltage supply: The secondary side of the igni- C.

  • Page 461: Current Measurement

    BRP-Rotax MAINTENANCE MANUAL HEAVY CURRENT MEASUREMENT General note It is not often necessary to measure the amperage on the engine. This requires an ammeter, which is usually integrated in a multimeter. Voltage supply NOTICE Amperage: Never measure the amperage in the...
  • Page 462 BRP-Rotax MAINTENANCE MANUAL HEAVY MANIFOLD AIR PRESSURE SENSOR (MAPS_1/MAPS_2) — INSPECTION Step Procedure Inspect for physical damage. Measure the amps between pin B and C. Manifold air pressure sensor (MAPS_1, MAPS_2) Voltage [in V] Remarks Signal 5 V ± 0.5 Supply voltage 0.5 ..

  • Page 463: Oil Temperature Sensor (Ots) - Inspection

    BRP-Rotax MAINTENANCE MANUAL HEAVY Oil pressure sensor (OPS) Signal Voltage [in V] Remarks Measurement Pressure (bar/psi) Current [in V] 10 bar / 145 psi 4.5 V 10079 Figure 20.25 MANIFOLD AIR TEMPERATURE SENSOR (MATS_1/MATS_2) — INSPECTION Procedure Step Inspect for physical damage.
  • Page 464 BRP-Rotax MAINTENANCE MANUAL HEAVY Oil temperature sensor (OTS) Measurement Temperature [°C/°F] Resistance [Ω] - 10 °C / 14 °F 9395 +/- 7 % 0 °C / 32 °F 5895 +/- 7 % 20 °C / 68 °F 2499 +/-6 % 80 °C / 176 °F...

  • Page 465: Knock Sensor (Knock) - Inspection

    BRP-Rotax MAINTENANCE MANUAL HEAVY Exhaust gas temperature sensor (EGT 1, EGT 2, EGT 3, EGT 4) Measurement Temperature [°C/°F] Resistance [Ω] 169.7 -40 °C/-40 °F 0/32 °F 200.5 50 °C/122 °F 238.5 100 °C/212 °F 275.9 10080 200 °C/392 °F Figure 20.29...
  • Page 466 BRP-Rotax MAINTENANCE MANUAL HEAVY • Check the O-ring on the crankshaft position sensor • Check the thread • Check the crankshaft position sensor surface • Check the crankshaft position sensor bore NOTE CPS sensors cannot be tested for voltage and/or resistance. If the function is not given and/or an er- ror occurs, please renew the sensor.
  • Page 467 BRP-Rotax MAINTENANCE MANUAL HEAVY AMBIENT AIR PRESSURE AND TEMPERATURE SENSOR (AAPTS) — INSPECTION Step Procedure Inspect for physical damage. Measure the resistance for the temperature reading between pin 1 and 2. Measure the voltage for the pressure reading between pin 1 and 4.

  • Page 468: Double Ignition Coil - Inspection

    BRP-Rotax MAINTENANCE MANUAL HEAVY • Check the "spray pattern" using the map NOTICE Risk of damage to engine management system components! There is a risk of a permanent bypass (fuel pressure surge). Voltage and resistance test The internal resistance between pin 1 and 2 is about 12 Ω...
  • Page 469 BRP-Rotax MAINTENANCE MANUAL HEAVY IGNITION CABLES — INSPECTION NOTICE Cracking and other obvious damage to the ignition cables are not permitted! If in doubt, always re- place the cables and connectors. General visual inspection • Check for corrosion or damage to the ignition cables Continuity check •...

  • Page 470: Installation

    BRP-Rotax MAINTENANCE MANUAL HEAVY INSTALLATION Preparation • Clean all parts carefully • Remove protective coverings OIL PRESSURE SENSOR (OPS) — INSTALLATION Step Procedure Clean the thread of the oil pressure Figure 20.36 sensor. Apply LOCTITE 243 to the thread of the...
  • Page 471 BRP-Rotax MAINTENANCE MANUAL HEAVY Step Procedure The sensor is connected and discon- nected in the same way. See . COOLANT TEMPERATURE SENSOR (CTS) — INSTALLATION Step Procedure Clean the thread of the coolant tempera- ture sensor. Apply LOCTITE 243 to the thread of the coolant temperature sensor and use a 19 Figure 20.37...

  • Page 472: Oil Temperature Sensor (Ots) - Installation

    BRP-Rotax MAINTENANCE MANUAL HEAVY MANIFOLD AIR TEMPERATURE SENSOR (MATS_1/MATS_2) — INSTALLATION Step Procedure Clean the thread of the manifold air tem- perature sensor. Install manifold air temperature sensor with the connector bracket and new seal- ing ring A12x18 using a 19 mm socket (part no.
  • Page 473 BRP-Rotax MAINTENANCE MANUAL HEAVY EXHAUST GAS TEMPERATURE SENSOR — INSTALLATION Procedure Step Clean the thread of the temperature sensor. Apply LOCTITE ANTI SEIZE to the thread of the exhaust gas temperature sensor. Tighten the exhaust gas temperature sen- sors on the exhaust pipes. Tightening tor- que 25 Nm (18 ft.lb.).

  • Page 474: Knock Sensor (Knock) - Installation

    BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 20.45 Figure 20.46 Connector (EGT) Knock sensor Connector bracket Hex. screw M8x30 (KNOCK) KNOCK SENSOR (KNOCK) — Step Procedure INSTALLATION Connect the respective wiring harness NOTE connector (KNOCK) to the knock sensor. Only necessary with old wiring harness.
  • Page 475 BRP-Rotax MAINTENANCE MANUAL HEAVY Step Procedure Step Procedure Attach the cables of the knock sensor Place CPS_1 into the upper sensor posi- with 2 cable ties. tion and CPS_2 into lower position. Tight- en crankshaft position sensors using Allen screws M6x20 with lock washers A6 and secure with LOCTITE 243.

  • Page 476: Throttle Potentiometer (Tps) - Installation

    BRP-Rotax MAINTENANCE MANUAL HEAVY THROTTLE POTENTIOMETER (TPS) — NOTICE INSTALLATION The thread of the Allen screw M6x50 reaches NOTE into the crankcase and is therefore glued in with LOCTITE 243. Improper installation can The throttle position is not available as a spare cause an oil leakage! part.

  • Page 477: Finishing Work

    BRP-Rotax MAINTENANCE MANUAL HEAVY FINISHING WORK • Complete the engine Fill with operating fluids (coolant, oil or fuel). See current Maintenance Manual Line (MML) for the respective engine type. Flush the engine cooling system. See current Maintenance Manual Line (MML) for the respective engine type, Chapter 12-20-00 section Flushing the en- gine cooling system.
  • Page 478 BRP-Rotax MAINTENANCE MANUAL HEAVY INTENTIONALLY LEFT BLANK Page 36 Effectivity: 912 i Series Edition 2 / June 01 2024 Rev. 0...

  • Page 479: Exhaust System

    BRP-Rotax MAINTENANCE MANUAL HEAVY Chapter: 78–00–00 EXHAUST SYSTEM TOPICS IN THIS CHAPTER System description ..........................3 Exhaust flow ............................3 Exhaust Gas Temperature Sensors (EGT)....................3 Safety instruction...........................3 Connections for display systems......................3 Exhaust gas temperature display ......................3 Effectivity: 912 i Series 78–00–00 Rev. 0...
  • Page 480 BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 21.1: Location on the engine 78–00–00 Effectivity: 912 i Series Rev. 0 Page 2 Edition 2 / June 01 2024...
  • Page 481 BRP-Rotax MAINTENANCE MANUAL HEAVY SYSTEM DESCRIPTION can be installed in various ways depending on the exhaust system. The exhaust system of the ROTAX® 912 i Series en- gine is optional. If it was not ordered when the engine was purchased, only the 4 exhaust sockets on the NOTICE cylinder head are supplied.
  • Page 482 BRP-Rotax MAINTENANCE MANUAL HEAVY INTENTIONALLY LEFT BLANK Page 4 Effectivity: 912 i Series Edition 2 / June 01 2024 Rev. 0...
  • Page 483 BRP-Rotax MAINTENANCE MANUAL HEAVY Chapter: 78–10–00 EXHAUST TOPICS IN THIS CHAPTER Service products .............................3 System description ..........................4 Maintenance ............................4 Removal ..............................5 Exhaust assy. — removal ........................5 Exhaust pipe — removal ........................5 Inspection ...............................6 Exhaust assy. — inspection........................6 Exhaust pipe and cylinder head — inspection ..................6 Installation...............................7...
  • Page 484 BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 22.1: Exhaust system Muffler assy. Tension spring Exhaust pipe Exhaust Gas Temperature Sensors (EGT) Exhaust flange Outflow pipe / exhaust elbow / tailpipe 78–10–00 Effectivity: 912 i Series Rev. 0 Page 2 Edition 2 / June 01 2024...
  • Page 485 BRP-Rotax MAINTENANCE MANUAL HEAVY SERVICE PRODUCTS Description Part number LOCTITE 648 899788 LOCTITE ANTI SEIZE 297434 Figure 22.2: Exhaust system Effectivity: 912 i Series 78–10–00 Rev. 0 Page 3 Edition 2 / June 01 2024...
  • Page 486 BRP-Rotax MAINTENANCE MANUAL HEAVY SYSTEM DESCRIPTION The exhaust gases are pushed out of the cylinders through the exhaust pipes and are brought together in the muffler assy.. From there the exhaust gases leave the engine through the exhaust elbow. MAINTENANCE...

  • Page 487: Exhaust Pipe Removal

    BRP-Rotax MAINTENANCE MANUAL HEAVY REMOVAL m WARNING Danger of severe burns and scalds! Allow the engine and exhaust system to cool to ambient temperature before starting work. Follow the aircraft manufacturer's instruc- tions for removal. EXHAUST ASSY. — REMOVAL Preparation •...

  • Page 488: Exhaust Assy. - Inspection

    BRP-Rotax MAINTENANCE MANUAL HEAVY INSPECTION Preparation Clean all parts carefully. See current Maintenance Manual Line (MML) of the respective engine type, Chapter 05-00-00 section Procedure. EXHAUST ASSY. — INSPECTION Follow the aircraft manufacturer's instruc- tions for inspection. Step Procedure Figure 22.5: Typical...
  • Page 489 BRP-Rotax MAINTENANCE MANUAL HEAVY INSTALLATION Follow the aircraft manufacturer's instruc- tions for installation. EXHAUST ASSY. — INSTALLATION Step Procedure Check that the studs are firmly in place. Secure them with LOCTITE 648 if neces- sary and tighten them. Tightening torque 6 Nm (53 in. lb.) Mount exhaust pipes 3 and 4 into the muffler assy.

  • Page 490: Finishing Work

    BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 22.8 Exhaust flange Lock nut M8 Exhaust pipe Cylinder head Step Procedure Attach the safety wire of the springs. Install exhaust elbow, follow the aircraft manufacturer’s instructions for installation. FINISHING WORK Install the Exhaust Gas Temperature Sen- sor (EGT).
  • Page 491 BRP-Rotax MAINTENANCE MANUAL HEAVY Chapter: 79–00–00 LUBRICATION SYSTEM TOPICS IN THIS CHAPTER Special tools............................3 Service products .............................4 System description ..........................6 Oil flow ..............................6 Crankcase ............................6 Oil pump ...............................6 Safety instruction...........................6 Connections for display systems......................6 Oil temperature sensor (OTS).........................6 Oil pressure sensor (OPS) ........................6 Maintenance ............................6...
  • Page 492 BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 23.1: Location on the engine 79–00–00 Effectivity: 912 i Series Rev. 0 Page 2 Edition 2 / June 01 2024...
  • Page 493 BRP-Rotax MAINTENANCE MANUAL HEAVY SPECIAL TOOLS Description Part number Oil filter wrench 877620 Socket wrench 876075 876130 Socket wrench Figure 23.2: Special tools Effectivity: 912 i Series 79–00–00 Rev. 0 Page 3 Edition 2 / June 01 2024...
  • Page 494 BRP-Rotax MAINTENANCE MANUAL HEAVY SERVICE PRODUCTS Description Part number LOCTITE ANTI SEIZE 898351 LOCTITE 5910 899791 897651 LOCTITE 243 LOCTITE 648 899788 n.a. Engine oil n.a. Insulating tape 898570 LOCKING PAINT 79–00–00 Effectivity: 912 i Series Rev. 0 Page 4...
  • Page 495 BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 23.3: Lubrication system Effectivity: 912 i Series 79–00–00 Rev. 0 Page 5 Edition 2 / June 01 2024...
  • Page 496 BRP-Rotax MAINTENANCE MANUAL HEAVY SYSTEM DESCRIPTION ENVIRONMENTAL NOTE The engine is provided with a dry sump forced lubri- Please observe the disposal regulations appli- cation system with a main oil pump with integrated cable in your area. pressure regulator. OIL FLOW...

  • Page 497: Oil Pump

    BRP-Rotax MAINTENANCE MANUAL HEAVY OIL PUMP NOTICE OIL PUMP ASSY. REMOVAL All gaskets, O-rings and oil seals must be replaced! m WARNING Step Procedure Danger of severe burns and scalds! Always al- low the engine to cool down to ambient tem- Disconnect the pressure oil lines.

  • Page 498: Oil Pump - Disassembly

    BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 23.5 Filter wrench part no. Figure 23.7 Oil filter 877620 Plug screw Compression spring Step Procedure Regulating piston Loosen 4 Allen screws with washers. Remove the whole oil pump unit and O- Step Procedure rings.
  • Page 499 BRP-Rotax MAINTENANCE MANUAL HEAVY NOTICE NOTICE The rotary piston and rotor are marked. The sealing lip of the oil seal is damaged when the oil pump shaft is pulled out and must be replaced. Figure 23.9 Figure 23.10 Rotary piston (outer...

  • Page 500: Oil Pump Housing - Inspection

    BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 23.13 Figure 23.12 Straight-edge Oil pump cover Oil pump center Screwdriver Oil seal housing OIL PUMP SINGLE PARTS — Step Procedure INSPECTION Check the sealing faces of the oil pump Preparation housing and pump cover for striations.

  • Page 501: Rotary Piston/Rotor - Inspection

    BRP-Rotax MAINTENANCE MANUAL HEAVY ROTARY PISTON/ROTOR — OIL PUMP SHAFT — INSPECTION INSPECTION Step Procedure Procedure Step Check the oil pump shaft at the bearing points. Check the rotary piston and rotor for grooves. Check the feather key groove and feather key for wear.
  • Page 502 BRP-Rotax MAINTENANCE MANUAL HEAVY WEAR LIMITS Figure 23.17: Oil pump Description Current measurement Tolerance Tolerance Code Measure- value limit limit ments 100 % 50 % Main pump 0.02 mm 0.07 mm 0.20 mm 0.14 mm current OP01 spacing (pump replaced 0.00079 in.

  • Page 503: Oil Pump - Assembly

    BRP-Rotax MAINTENANCE MANUAL HEAVY OIL PUMP — ASSEMBLY Step Procedure Apply LOCTITE ANTI SEIZE on the thread of the plug screw. Install oiled regulating piston and com- pression spring in the oil pump housing and hand-tighten the plug screw M22x1.5.
  • Page 504 BRP-Rotax MAINTENANCE MANUAL HEAVY NOTICE If the oil pump shaft is pulled out again, re- place the oil seal (unusable). Step Procedure Insert the feather key A4x4x8 in the oil pump shaft. Figure 23.22 Rotary piston (outer Rotor (inner rotor) rotor) O-ring 63–2.5...

  • Page 505: Oil Pump Installation

    BRP-Rotax MAINTENANCE MANUAL HEAVY OIL PUMP — INSTALLATION Preparation • Check the fit of the O-rings on the oil pump housing. NOTICE Ensure that the oil pump shaft is in the correct installation position. Figure 23.23 Oil pump cover OIL PUMP HOUSING O-RINGS...

  • Page 506: Oil Filter - Installation

    BRP-Rotax MAINTENANCE MANUAL HEAVY Step Procedure If necessary install oil filter nipple. Tightening torque 60 Nm (44 ft. lb.). If necessary install plug screw A M16x1.5 with new sealing ring A 16x22. Tightening torque 35 Nm (26 ft. lb.). If necessary apply LOCTITE 648 on the Adapter metric or UNF (Oil inlet) and in- stall with new sealing ring A 16x22.
  • Page 507 BRP-Rotax MAINTENANCE MANUAL HEAVY Fill with operating fluids or check filling levels. See current Maintenance Manual Line (MML) for the respective engine type, Chapter 12–10–00 section Adding operat- ing fluids. Purge the oil system. See current Installation Manual (IM) for...

  • Page 508: Oil Tank - Disassembly

    BRP-Rotax MAINTENANCE MANUAL HEAVY OIL TANK OIL TANK — REMOVAL m WARNING Danger of severe burns and scalds! Always allow the engine to cool down to ambient temperature before starting any work. ENVIRONMENTAL NOTE Dispose of used oil according to local environ- mental regulations.

  • Page 509: Oil Tank - Assembly

    BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 23.32 Figure 23.31 Oil tank Partition Baffle insert (screen) Gasket ring Oil tank cover assy. Oil tank Hex. screw O-Ring Profile clamp 163 OIL TANK SINGLE PARTS — Step Procedure INSPECTION Remove the baffle insert (screen) and Clean all parts carefully.

  • Page 510: Oil Tank - Installation

    BRP-Rotax MAINTENANCE MANUAL HEAVY Purge the oil system. See current Installation Manual (IM) for the respective engine type, Chapter 79-00-00 section Purging the lubrication system. Carry out an engine test run. See current Maintenance Manual Line (MML) for the respective engine type,...

  • Page 511: Oil Lines

    BRP-Rotax MAINTENANCE MANUAL HEAVY OIL LINES OIL LINE (STEEL LINE) – REMOVAL m WARNING NOTICE Danger of severe burns and scalds! The steel oil lines (scope of delivery) must be Always allow the engine to cool down to ambient removed only, if they are damaged or for main- temperature before starting any work.
  • Page 512 BRP-Rotax MAINTENANCE MANUAL HEAVY OIL LINE (STEEL LINE) INSTALLATION CHECK VALVE For information of the check valve, see the Step Procedure current documentation of the aircraft For installation of the pressure oil line. manufacturer. Chapter 61-20-00 section Governor. OIL COOLER OIL HOSES —...

  • Page 513: Electric Starter

    BRP-Rotax MAINTENANCE MANUAL HEAVY Chapter: 80–00–00 ELECTRIC STARTER TOPICS IN THIS CHAPTER Service products .............................3 System description ..........................4 Safety instruction...........................4 Maintenance ............................4 Electric starter ............................5 Electric starter — removal ........................5 Electric starter inspection ........................5 Electric starter — installation ........................6 Finishing work ............................7 Effectivity: 912 i Series 80–00–00...
  • Page 514 BRP-Rotax MAINTENANCE MANUAL HEAVY Figure 24.1: Location on the engine 80–00–00 Effectivity: 912 i Series Rev. 0 Page 2 Edition 2 / June 01 2024...
  • Page 515 BRP-Rotax MAINTENANCE MANUAL HEAVY SERVICE PRODUCTS Description Part number LOCTITE ANTI SEIZE 8151 297434 LOCKING PAINT 898570 Figure 24.2: Electric starter Effectivity: 912 i Series 80–00–00 Rev. 0 Page 3 Edition 2 / June 01 2024...
  • Page 516 BRP-Rotax MAINTENANCE MANUAL HEAVY SYSTEM DESCRIPTION NOTICE The electric starter is a DC motor with a permanent Danger of damage to engine! There is a risk of magnet and carbon brushes. The geartooth system short circuits and cable fires during work on...

  • Page 517: Electric Starter - Removal

    BRP-Rotax MAINTENANCE MANUAL HEAVY ELECTRIC STARTER NOTICE NOTE Hold the Mx145 hex. screw still with a suitable tool! For idle gear and idle gear shaft. See Chapter Do not unscrew or remove the long M5 screws! 72–20–00 Sprag clutch housing – removal...

  • Page 518: Electric Starter - Installation

    BRP-Rotax MAINTENANCE MANUAL HEAVY NOTICE NOTICE Ensure that the electric starter is in the correct Disassembly of starter assy. is not allowed! installation position. Procedure Step Install new O-ring 24.4x3x1 onto the elec- tric starter flange greased with LOCTITE ANTI SEIZE.
  • Page 519 BRP-Rotax MAINTENANCE MANUAL HEAVY Step Procedure Connect the positive pole on the electric starter. Tightening torque 4 Nm (35 in. lb.). Figure 24.7 Positive (+) cable Terminal screw M5x8 Lock washer A5 FINISHING WORK • Connect the negative terminal of the onboard bat- tery according to the aircraft manufacturer's instruction.
  • Page 520 BRP-Rotax MAINTENANCE MANUAL HEAVY INTENTIONALLY LEFT BLANK Page 8 Effectivity: 912 i Series Edition 2 / June 01 2024 Rev. 0...
  • Page 521 BRP-Rotax MAINTENANCE MANUAL HEAVY Index Coolant Temperature sensor — disconnection..12 Coolant temperature sensor (CTS) — Abbreviations............4 connection ............23 Adjustment of the disc spring pretension ....29 Coolant temperature sensor (CTS) — installation ..29 Air filter — inspection...........26 Coolant temperature sensor (CTS) — removal ..13 Airbox —...
  • Page 522 BRP-Rotax MAINTENANCE MANUAL HEAVY Double ignition coil – removal.........7 Flake pitting (large-area flank fractures) ....21 Double ignition coil — inspection ......26 fly wheel assy. installation ........33 Double ignition coil — installation ....13, 15, 34 Fly wheel assy. removal........16 Double ignition coil — removal ......16 Fly wheel assy., installation ........30...
  • Page 523 BRP-Rotax MAINTENANCE MANUAL HEAVY Governor flange — installation ......14 Governor flange — removal ........7 List of effective pages ..........1 Governor installation ...........16 LOCTITE Application procedure......26 Hardness test method ........15, 11 Maintenance............24 HIC A and HIC B — disconnection......8 Maintenance Concept..........15 HIC_A and _HIC_B —...
  • Page 524 BRP-Rotax MAINTENANCE MANUAL HEAVY Oil pressure sensor (OPS) — installation ....28 Regulator B — installation........11 Oil pump...............7 Regulator B — removal..........5 Oil pump – assembly ...........13 Removal..........14, 7, 6, 7, 5 Oil pump – disassembly.........8 Removal of the ball bearing........10 Oil pump –...
  • Page 525 BRP-Rotax MAINTENANCE MANUAL HEAVY Starter idle gear – inspection........ 11 Vacuum pump — removal ........7 Starter relay — connection........24 Vacuum pump gear - inspection ......10 starter relay — disconnection .........8 Vacuum pump gear – installation ......11 Stator assy. and flywheel assy. — inspection ..22 Valve - inspection ..........16...
  • Page 526 Engine serial no. Type of aircraft Aircraft registration no. Rotax® authorized distributor FLYROTAX.COM ® and TM are trademarks of BRP-Rotax GmbH & Co KG. 2024 BRP-Rotax GmbH & Co KG. All rights reserved. ©...

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