Rotax 912 Series Maintenance Manual
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Rotax 912 Series Maintenance Manual

912/914 series
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Table of Contents

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See also: Operator's Manual , Installation Manual
�������� �������
MAINTENANCE MANUAL
FOR ROTAX® ENGINE TYPES
(HEAVY MAINTENANCE)
picture 914 UL 3 DCDI with options
picture 912 ULS 3 DCDI with options
ROTAX ® 912 AND 914 SERIES
part no.: 899603

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Need help?

Need help?

Do you have a question about the 912 Series and is the answer not in the manual?

Questions and answers

Darrell Athey
February 17, 2025

I have a Rotax 912uls engine, how do I identify which cylinder is number one, two, three and four.

0
1 comments:
Mr. Anderson
February 17, 2025

The cylinder numbering for a Rotax 912 ULS engine follows this pattern:

- Cylinder 1 and Cylinder 3 are on one side of the engine.
- Cylinder 2 and Cylinder 4 are on the opposite side.

From the provided context, the numbering appears as:
- Cyl. 1 (Cylinder 1)
- Cyl. 2 (Cylinder 2)
- Cyl. 3 (Cylinder 3)
- Cyl. 4 (Cylinder 4)

Additionally, the document includes a side view of Cylinders 2 and 4, indicating their relative position in the engine layout.

This answer is automatically generated

0

Related Manuals for Rotax 912 Series

Summary of Contents for Rotax 912 Series

  • Page 1 �������� ������� MAINTENANCE MANUAL FOR ROTAX® ENGINE TYPES (HEAVY MAINTENANCE) picture 914 UL 3 DCDI with options picture 912 ULS 3 DCDI with options ROTAX ® 912 AND 914 SERIES part no.: 899603...
  • Page 2 Rotax GmbH&Co. KG, Austria, acc, BGBI 1984 no. 448, and shall not, without prior written permission of BRP-Rotax GmbH&Co. KG, be disclosed in whole or in part to third parties. This legend shall be included on any reproduction of these data, in whole or in part.

  • Page 3: Table Of Contents

    BRP-Rotax Maintenance Manual SECTION 00 INTRODUCTION 1) Table of contents SECTION 00 INTRODUCTION 1) Table of contents ..................00-00-00 / 3 2) List of chapters ..................00-00-00 / 5 3) Index ....................... 00-00-00 / 7 4) List of the valid pages ................00-00-00 / 11 5) Table of amendments ................
  • Page 4 BRP-Rotax Maintenance Manual NOTES 00-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 4 May 01/2007...

  • Page 5: List Of Chapters

    BRP-Rotax Maintenance Manual 2) List of chapters INTRODUCTION ..........00 POWER PLANT ..........71 ENGINE ............72 FUEL SYSTEM ..........73 IGNITION SYSTEM .......... 74 COOLING SYSTEM .......... 75 ENGINE CONTROL .......... 76 EXHAUST SYSTEM AND TURBOCHARGER .. 78 LUBRICATION SYSTEM ........79 ELECTRIC STARTER ........
  • Page 6 BRP-Rotax Maintenance Manual NOTES 00-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 6 May 01/2007...

  • Page 7: Index

    BRP-Rotax Maintenance Manual 3) Index Cylinders removal 72-00-00 / 75 3way solenoid valve inspection 76-00-00 / 53 Description of design 71-00-00 / 3 Devices 00-00-00 / 38 Abrasives 00-00-00 / 34 Diaphragms 73-00-00 / 25 Airbox temperature 76-00-00 / 9...
  • Page 8 BRP-Rotax Maintenance Manual Magnetic plug 79-00-00 / 10 Gas bowden cable inspection 73-00-00 / 33 Main oil pump 79-00-00 / 3, 79-00-00 / 5 Gas bowden cable inspection 73-00-00 / 33 Measuring tools 00-00-00 / 37 Gear set inspection 72-00-00 / 44...
  • Page 9 BRP-Rotax Maintenance Manual Table of amendments 00-00-00 / 17 Red boost lamp 76-00-00 / 11 Target pressure reduction 76-00-00 / 8 Return to service 00-00-00 / 25, 71-00-00 / 17, 71- TCU inspection 76-00-00 / 32 00-00 / 18 Technical data 71-00-00 / 11, 71-00-00 / 15...
  • Page 10 BRP-Rotax Maintenance Manual NOTES 00-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 10 May 01/2007...

  • Page 11: List Of The Valid Pages

    BRP-Rotax Maintenance Manual 4) List of the valid pages 02708 Chapter Page Chapter Page Date Date 43 05 01 2007 Cover page 44 05 01 2007 00-00-00 1 05 01 2007 45 05 01 2007 2 05 01 2007 46 05 01 2007...
  • Page 12 BRP-Rotax Maintenance Manual Chapter Page Chapter Page Date Date 61 05 01 2007 18 05 01 2007 62 05 01 2007 19 05 01 2007 63 05 01 2007 20 05 01 2007 64 05 01 2007 21 05 01 2007...
  • Page 13 BRP-Rotax Maintenance Manual Chapter Page Chapter Page Date Date 104 05 01 2007 29 05 01 2007 105 05 01 2007 30 05 01 2007 106 05 01 2007 31 05 01 2007 107 05 01 2007 32 05 01 2007...
  • Page 14 BRP-Rotax Maintenance Manual Chapter Page Chapter Page Date Date 53 05 01 2007 10 05 01 2007 54 05 01 2007 11 05 01 2007 55 05 01 2007 12 05 01 2007 56 05 01 2007 13 05 01 2007...
  • Page 15 BRP-Rotax Maintenance Manual Chapter Page Chapter Page Date Date 12 05 01 2007 55 05 01 2007 13 05 01 2007 56 05 01 2007 14 05 01 2007 78-00-00 1 05 01 2007 15 05 01 2007 2 05 01 2007...
  • Page 16 BRP-Rotax Maintenance Manual Chapter Page Chapter Page Date Date 19 05 01 2007 20 05 01 2007 21 05 01 2007 22 05 01 2007 23 05 01 2007 24 05 01 2007 25 05 01 2007 26 05 01 2007...
  • Page 17 BRP-Rotax Maintenance Manual NOTES 00-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 17 May 01/2007...
  • Page 18 BRP-Rotax Maintenance Manual NOTES 00-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 18 May 01/2007...

  • Page 19: Table Of Amendments

    BRP-Rotax Maintenance Manual 5) Table of amendments *Approval The technical content of this document is approved under the authority of DOA Nr. EASA.21J.048. 08215 Ser. Date Sign Date of Date of Sign/ Section Pages accept. of implemen- Signature correction acceptance resp.
  • Page 20 BRP-Rotax Maintenance Manual NOTES 00-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 20 May 01/2007...

  • Page 21: General Note

    Before carrying out maintenance work on the engine, please read the Maintenance Manual (Heavy Maintenance) carefully. See also the corresponding Maintenance Manual (Line Maintenance) for the respective engine type 912 Series, part no . 899372, or 914 Series, part no. 899606.
  • Page 22 BRP-Rotax Maintenance Manual NOTES 00-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 22 May 01/2007...

  • Page 23: Safety Notice

    The information and components/system descriptions contained in this Maintenance Manual are correct at the time of publication. BRP-Rotax maintains a policy of continuous improvement of its products, without, however, incurring any obligation to install them on its products previously manufactured.
  • Page 24 BRP-Rotax Maintenance Manual NOTES 00-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 24 May 01/2007...

  • Page 25: Technical Documentation

    BRP-Rotax Maintenance Manual 8) Technical documentation See also the corresponding Maintenance Manual (Line Maintenance) for the re- spective engine type 912 Series or 914 Series. 8.1) Filling in the dimension sheets See Fig. 00-1 All measurements must be entered in the corresponding dimension sheets as shown.

  • Page 26: List Of Abbreviations

    BRP-Rotax Maintenance Manual Dimensional check of parts See Fig. 00-2 Take readings of all parts listed in the dimension sheets. Enter the respective actual value in the dimension sheets attached directly after each section. ■ CAUTION: Where measurement values are taken in hundredths of a millimeter or more precisely, the temperature of the part must be 20 to 25 °C (68 to 77 °F).

  • Page 27: Classification Of Parts For Maintenance/Repair

    BRP-Rotax Maintenance Manual 9) Classification of parts for maintenance/repair See Figs. 00-3 and 00-4. As for an overhaul, parts for maintenance/repair must be classified. They are classified either as “parts usable” or as “parts to be replaced”. The classification is made on the basis of the following criteria: –...
  • Page 28 Plot the hours of operation [h] on the diagram, see Fig. 00-3. The maximum permissible wear [%] is located at the intersection with the curve. Fig . 00-3 07227 (parts to be replaced) 00-00-00 Effectivity 912 Series Edition 1 / Rev. 0 page 28 May 01/2007...
  • Page 29 BRP-Rotax Maintenance Manual For engines of Series 914: Plot the hours of operation [h] on the diagram, see Fig. 00-4. The maximum permissible wear [%] is located at the intersection with the curve. Fig . 00-4 07228 (parts to be replaced)

  • Page 30: Determination Of Actual Wear [%]

    BRP-Rotax Maintenance Manual 9.1) Determination of actual wear [%] See Figs. 00-5, 00-6 and 00-7. Determine actual dimension F of the part in question. For new dimension (max) B and wear limit C, see the corresponding section´Wear limits“ (e. g. 74-00-00 sec. 4).
  • Page 31 BRP-Rotax Maintenance Manual ■ CAUTION: New dimension (max) B is always the dimension which is closest to wear limit C. Fig. 00-7 07564 Procedure for classification of “On Condition Parts” at maintenance/ repair: ◆ NOTE: A negative result means that the actual dimension F is within the new dimension tolerance D.
  • Page 32 BRP-Rotax Maintenance Manual NOTES 00-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 32 May 01/2007...

  • Page 33: Maintenance

    The following sections describe maintenance procedure for engines of the 912/914 Series above and beyond the maintenance and special checks, see corresponding Maintenance Manual (Line Maintenance) for the respective engine type, 912 Series or 914 Series, and the systems descriptions given hitherto. The description is subdivided into subsections and descriptions of the function of the various systems.

  • Page 34: Consumable Materials

    BRP-Rotax Maintenance Manual 10.3) Consumable materials ▲ WARNING: Use only the specified or technically equivalent materials for all maintenance work. The materials listed have undergone longterm testing and are suitable for all operating conditions indicated by the manufacturer. ▲ WARNING: When handling chemicals, comply with all the customary regu- lations and specifications of the producer, including the expiry date.
  • Page 35 BRP-Rotax Maintenance Manual 14 899788 LOCTITE 648 green, heavy-duty screw locking agent ........5 ml 15 897186 SILICONE HEAT CONDUCTION COMPOUND ..150 g Application of the heat conduction compound will reduce heat transfer resistance. The greaselike, temperature- resistant silicon compound fills cavities between compo- nents and cooling elements (e.g: spark plug - cylinder...
  • Page 36 BRP-Rotax Maintenance Manual 21 n.e. Cleaning agent ▲ WARNING: Use only approved cleaning agents (e.g. gaso- line, kerosene, varsol, etc.) for cleaning metal parts. Do not use lyebased cold cleaners or degreasing agents. Do not clean coolant and oil hoses with aggressive solu- tions.

  • Page 37: Auxiliary Tools

    BRP-Rotax Maintenance Manual 10.4) Auxiliary tools – compression tester or 2 pressure gauges with calibrated orifice, adapter for dial gauge in spark plug thread – valve spring mounting pliers – step punch for valve guide – adjustable reamer 6.5 to 7.5 mm (0.256 to 0.295 in.) –...
  • Page 38 BRP-Rotax Maintenance Manual Disassembly device for propeller gearbox. Fig. 00-8 shows one possible tensioning device for the disassembly of the propeller gearbox. The dimensions given are only intended for easier orientation and are not binding. Fig. 00-8 (0.2 in.) (3.15 in.) (1.89 in.)

  • Page 39: Measuring Tools

    BRP-Rotax Maintenance Manual 10.5) Measuring tools Calliper rule, dial gauge indicator, micrometer, inner micrometer, inner fine measuring device, feeler gauge, spring scale up to 50 kp (500 N)(112.5 lbf). Stroboscope: BOSCH 0 684 100 308 or equivalent. Supply voltage 8 to 15 V.
  • Page 40 BRP-Rotax Maintenance Manual 10.6) Special tools and devices See Figs. 00-9, 00-10 and 00-11. The following tools and devices are also listed in the Illustrated Parts Catalog. Fig. No.Part No. Description, application Number 276282 spark plug wrench a/f 16 ........1 276280 spark plug wrench a/f 18 ........
  • Page 41 BRP-Rotax Maintenance Manual Fig. No.Part No. Description, application Number 877295 piston ring retainer assy........1 for water pump impeller 240381 hex. screw M6x12 ..........1 for float level gauge 17-18 877730 float level gauge assy., .......... 1 for check of float lever 877320 press-in ring ............
  • Page 42 BRP-Rotax Maintenance Manual Fig. No.Part No. Description, application Number 877315 graduated straightedge assy......... 1 for checking the plain bearing projection 876950 precision dial gauge ..........1 877710 dial gauge adapter assy., ........1 877300 aligning plate ............1 877262 cylinder aligning tool ..........
  • Page 43 BRP-Rotax Maintenance Manual Fig. No.Part No. Description, application Number 842585 hex. nut M24x1.5 length 19 ........1 941180 stud M10x45/20 ............. 1 for roller bearing 25x52x15 and oil seal 30x52x7 877600 press-out mushroom ..........1 for propeller shaft F3 and F4 877605 press-out mushroom ..........
  • Page 44 BRP-Rotax Maintenance Manual Fig. 00-9 08201 00-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 44 May 01/2007...
  • Page 45 BRP-Rotax Maintenance Manual Fig. 00-10 08202 00-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 45 May 01/2007...
  • Page 46 BRP-Rotax Maintenance Manual Fig. 00-11 08203 00-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 46 May 01/2007...
  • Page 47 BRP-Rotax Maintenance Manual SECTION 71 POWER PLANT 1) Table of contents SECTION 71 POWER PLANT 1) Table of contents ..................71-00-00 / 1 2) System description ................. 71-00-00 / 3 2.1) Description of design ..............71-00-00 / 3 2.2) Type description ................71-00-00 / 4 2.3) Engine components, engine views, cylinder designation...
  • Page 48 BRP-Rotax Maintenance Manual NOTES 71-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 2 May 01/2007...

  • Page 49: System Description

    All ROTAX engines of the 912/914 Series consist of several main components and additional aggregates which are described in the following sections. On the 912 Series: 4-cylinder horizontally opposed 4 stroke engine with a central camshaft pushrods OHV. On the 914 Series: 4-cylinder horizontally opposed 4 stroke engine with turbo-...

  • Page 50: Type Description

    BRP-Rotax Maintenance Manual 2.2) Type description e.g. ROTAX 914 F 2 ◆ NOTE: The type description is composed as follows: ROTAX 02091 Type: 914 4-cylinder horizontally opposed turbo engine Certification: F certified in accordance with FAR/ JAR-E (TW10 - ACG)
  • Page 51 2.3) Engine components, engine views, cylinder designation and descrip- tion of main axes See Figs. 71-1 to 71-4 for engines of the 912 Series See Figs. 71-5 to 71-9 for engines of the 914 Series AS power take off side...
  • Page 52 Engine suspension frame (optional) (22) Oil tank (10) Coolant pump ( 23) External alternator (11) Expansion tank (24) Magnetic plug (12) Oil pump (25) Fuel pump 71-00-00 Effectivity 912 Series Edition 1 / Rev. 0 page 6 May 01/2007...
  • Page 53 Maintenance Manual 912 Series Fig. 71-2 00503 Front view Fig. 71-4 912 Series Fig. 71-3 00124 Cyl. 3 Cyl. 4 Cyl. 2 Cyl. 1 Top view 07902 71-00-00 Effectivity 912 Series Edition 1 / Rev. 0 page 7 May 01/2007...
  • Page 54 BRP-Rotax Maintenance Manual 914 Series Side view Cyl. 2-4 00120 Fig. 71-5 Engine number (24) Electric starter Propeller flange (25) Electronic module Propeller gearbox (26) Compensation tube Vacuum pump or hydraulically controlled (27) Connection for boost pressure display constant speed propeller governor...
  • Page 55 BRP-Rotax Maintenance Manual 914 Series Fig. 71-6 Front view 00121 914 Series Fig. 71-7 00123 Fig. 71-8 Cyl. 4 Cyl. 3 Cyl. 2 Cyl. 1 Fig. 71-9 00122 Top view 00124 71-00-00 Effectivity 914 Series Edition 1 / Rev. 0...
  • Page 56 BRP-Rotax Maintenance Manual NOTES 71-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 10 May 01/2007...

  • Page 57: Technical Data

    ■ CAUTION: The technical data relevant for engine operation are listed in detail in the respective Operators Manual and must be observed. 3.1) Operating limits See latest version of valid Operators Manual for the engine in question 912 Series or 914 Series, ¨Operating instructions“. 3.2) Operating fluids / Capacity See latest version of valid Operators Manual for the engine in question 912 Series or 914 Series, ¨Operating fluids“.

  • Page 58: Engine / Components

    BRP-Rotax Maintenance Manual 3.4) Engine / Components DESIGN: 4-cylinder horizontally opposed 4-stroke-engine 1) 3) BORE: 79.5 mm (3.13 in.) 84 mm (3.31 in.) STROKE: 61.0mm (2.40in.) 1) 3) DISPLACEMENT: 1211.2 cm³ 1352 cm³ CYLINDER: Lightweight metal cylinder with Nikasil coated...
  • Page 59 BRP-Rotax Maintenance Manual IGNITION UNIT: ROTAX DCDI, interference suppressed IGNITION POINT: at start: Circuit A and B:..4° B.T.D.C. during operation: Circuit A:....26° B.T.D.C. Circuit B 1) 2) :..26° B.T.D.C. Circuit B : ..22° B.T.D.C. FIRING ORDER: 1- 4 - 2 - 3 SPARK PLUGS: 12 mm (0.47 in.), DCPR7...
  • Page 60 BRP-Rotax Maintenance Manual TURBOCHARGER: Exhaust gas turbine with wastegate, radial-flow com- pressor T25 TURBOCHARGER CONTROL UNIT (TCU):electronic, proportional plus integral plus derivative regulator with 2 external indicating lamps CERTIFICATION: 912 A: in acc. with JAR 22 912 F: in acc. with FAR 33 912 S: in acc.

  • Page 61: Treatment Of Corrosion And Surface Damage

    BRP-Rotax Maintenance Manual 4) Treatment of corrosion and surface damage In the case of long standstill times, a rust film may form on various metal parts. Severely or heavily corroded screws, nuts, washers, bearings, bushes etc., must be replaced. 4.1)
  • Page 62 BRP-Rotax Maintenance Manual NOTES 71-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 16 May 01/2007...

  • Page 63: Preservation And Returning To Service

    ▲ WARNING: The engine must not be taken into operation. ◆ NOTE: The maximum possible storage period of the engine is limited to 24 months. If this period is exceeded, the engine must be sent to an ROTAX authorized overhaul facility for inspection. 71-00-00 Effectivity 912/914 Series Edition 1 / Rev.

  • Page 64: Preservation Of An Engine Which Has Been In Operation

    – Oil change see latest issue Maintenance Manual (Line Maintenance) for the respective engine type, 912 Series or 914 Series. – On the ROTAX 912 Series: Run the engine to allow it to warm up, leave it running at increased idle speed, remove the air filters and inject approx. 30 of preservation oil into the carburetors, shut down the engine.

  • Page 65: Maintenance

    The following sections describe maintenance procedure for engines of the 912/914 Series above and beyond the maintenance and special checks, see latest issue Maintenance Manual (Line Maintenance) for the respective engine type, 912 Series or 914 Series, and the systems descriptions given hitherto. The description is divided into subsections and descriptions of the function of the various systems.

  • Page 66: 2) Engine Suspension Frame Inspection

    BRP-Rotax Maintenance Manual 6.1.2) Engine suspension frame inspection See Fig. 71-11 – All components must be subjected to a visual inspection. ■ CAUTION: If the engine is fitted with engine suspension frame part no. 886567, inspection in accordance with SB-912-028 or SB-914-016,“Checking or replacement of engine...
  • Page 67 BRP-Rotax Maintenance Manual Fig. 71-10 00164 Fig. 71-11 03080 71-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 21 May 01/2007...

  • Page 68: Temperature- And Pressure Observation

    6.2) Temperature- and pressure observation Engines of the 912 Series and 914 Series are equipped with two tempera- ture control points on the cylinder heads for the coolant, one temperature control point for the oil temperature and a pressure control point for the oil pressure.
  • Page 69 BRP-Rotax Maintenance Manual SECTION 72 ENGINE 1) Table of contents SECTION 72 ENGINE 1) Table of contents ..................72-00-00 / 1 2) Systems description ................. 72-00-00 / 5 2.1) Propeller gearbox ................72-00-00 / 5 2.1.1) Gearbox version ..............72-00-00 / 5 2.2) Hydraulic governor ................
  • Page 70 BRP-Rotax Maintenance Manual 3.9) Propeller gearbox ................72-00-00 / 22 3.9.1) Removal of roller bearing for - Series 2 ........ 72-00-00 / 24 3.9.2) Removal of roller bearing for - Series 3 ........ 72-00-00 / 26 3.9.3) Removal of roller bearing for - Series 4 ........ 72-00-00 / 27 3.9.4) Propeller gearbox disassembly ..........
  • Page 71 4) Wear limits ....................72-00-00 / 97 5) Form Sheets ................... 72-00-00 / 117 5.1) Form sheet for material testing ROTAX 912/914 Series ....72-00-00 / 117 5.1.1) Inspection on cracks ............. 72-00-00 / 117 5.1.2) Hardness test ............... 72-00-00 / 117...
  • Page 72 BRP-Rotax Maintenance Manual NOTES 72-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 4 May 01/2007...

  • Page 73: Systems Description

    BRP-Rotax Maintenance Manual 2) Systems description 2.1) Propeller gearbox See Fig. 72 -1 2), 3), 4) Transmission gear ratio crankshaft: propeller shaft 2.43 : 1 ; 2.27 : 1 The propeller shaft is driven by the crankshaft via a straighttoothed spur gear (1).
  • Page 74 BRP-Rotax Maintenance Manual Fig. 72-1 08204 Configuration 3 with overload clutch 72-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 6 May 01/2007...

  • Page 75: Hydraulic Governor

    BRP-Rotax Maintenance Manual 2.2) Hydraulic governor See Fig. 72 -2 ◆ NOTE: Not included in the range of delivery. A hydraulic governor can be fitted on engines of the 912/914 Series configu- ration 3 to control a hydraulic constant speed propeller. Engines of the 912/ 914 Series configurations 2 and 4 can be retrofitted for this purpose.

  • Page 76: Vacuum Pump

    For connection of a rev counter, see 71-00-00 sec. 2.3 item no. 21 (on 912 Series) or item no. 32 (on 914 Series). The total transmission ratio from crankshaft to rev counter shaft i = 4 ◆...

  • Page 77: Maintenance

    The following sections describe maintenance procedure for engines of the 912/914 Series above and beyond the maintenance and special checks, see latest issue Maintenance Manual (Line Maintenance) for the respective engine type, 912 Series or 914 Series, and the systems descriptions given hitherto. The description is divided into subsections and descriptions of the function of the various systems.

  • Page 78: Vacuum Pump Removal And Inspection

    BRP-Rotax Maintenance Manual 3.2) Vacuum pump removal and inspection See Fig. 72-4. ■ CAUTION : Observe the vacuum pump manufacturers specifications for maintenance, inspection and repairs! Unscrew the 4 hex. nuts (1) M6 and remove the lock washers. Remove the vacuum pump (2) from the crankcase (4) together with the gasket and the retaining flange (3).

  • Page 79: Ignition Housing Removal And Inspection

    BRP-Rotax Maintenance Manual 3.4) Ignition housing removal and inspection See Figs. 72-5, 72-6, 72-7 and 72-8. Cut the tie wraps and remove the cable clamp from the electronic module. Detach the plug connections of the two pickup cables and the plug connections of the charging cable.
  • Page 80 BRP-Rotax Maintenance Manual Fig. 72-6 00381 00382 Carry out a visual inspection of the sealing surfaces. Clean oil duct (10) with compressed air and check for free passage. Mea- sure the bearing bore Ø32 (1.26“) mm of the bearing bushing (11) (dimen- sion (IH01)) for the crankshaft bearing (dimension (CS05)) and determine the clearance.
  • Page 81 BRP-Rotax Maintenance Manual Fig. 72-7 Fig. 72-8 00084 00383 72-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 13 May 01/2007...

  • Page 82: Ignition Housing Fitting

    BRP-Rotax Maintenance Manual 3.5) Ignition housing fitting See Fig. 72-9. Install the intermediate gear. See 72-00-00 sec. 3.7. ■ CAUTION: If the mounting sleeve, part no. 877360, is not used, the oil seal will be damaged by the sharp edge of the keyway in the crankshaft.

  • Page 83: Sprag Clutch

    BRP-Rotax Maintenance Manual 3.6) Sprag clutch See Figs. 72-10 and 72-12. After removing the fly wheel hub and the ignition housing, see 72-00-00 sec. 3.1 and 72-00-00 sec. 3.4, measure the axial clearance (ES10) of the free wheel gear (6).

  • Page 84: 1) Sprag Clutch Removal

    See Fig. 72-11. Lock the crankshaft. See the latest issue Maintenance Manual (Line Maintenance) for the respective engine type, 912 Series or 914 Series. Pull out the intermediate gear shaft (1) and remove the intermediate starter gear (2) with the thrust washers 12.5/21.5/1 (3) on both sides of the intermediate gear.

  • Page 85: 2) Sprag Clutch Dismantling

    BRP-Rotax Maintenance Manual 3.6.2) Sprag clutch dismantling See Figs. 72-12 and 72-13. Carry out a visual inspection to check whether oil sludge has been deposited in the sprag clutch housing (5) and in in the lock (16). For inspection/cleaning purposes, remove the circlip (14). Compress the circlip (19) in the sprag clutch (17) slightly with circlip pliers and twist the sprag unit out of the sprag clutch housing.

  • Page 86: 3) Sprag Clutch Installation

    BRP-Rotax Maintenance Manual 3.6.3) Sprag clutch installation See Figs. 72-10, 72-11, 72-12, 72-13, 72-14 and 72-15. Place the sprag clutch into the sprag clutch housing so that the circlip (19) is visible. To fit the circlip, compress it slightly using circlip pliers and ensure that clip remains in position and engages fully on the catches in the sprag unit (20).
  • Page 87 BRP-Rotax Maintenance Manual Secure degreased hex. nut M34x1.5 with LOCTITE 648 and tighten to 120 Nm (88.5 ft.lb). ◆ NOTE: Hex. nut with lefthanded thread. ■ CAUTION : Check axial clearance of free wheel gear, see Fig. 72-10 and dimension (ES10) in 72-00-00 sec. 4.

  • Page 88: Reduction Gear For Electric Starter

    BRP-Rotax Maintenance Manual 3.7) Reduction gear for electric starter See Fig. 72-16. Place thrust washer (1) 12.5/21.5/1 on the crankcase. Place interme- diate gear (2) in position, oil intermediate gear shaft (3) and push into position. Place thrust washer (4) 12.5/21.5/1 on top.

  • Page 89: Rev Counter Drive

    BRP-Rotax Maintenance Manual 3.8) Rev counter drive See Figs. 72-17, 72-18 and 72-19. The optional mechanical rev counter (1) is driven via the worm gear pressed into the camshaft. ◆ NOTE: On older engine versions without a mechanical rev counter, a cover plate is fitted in place of the rev counter housing.

  • Page 90: Propeller Gearbox

    Before removing the gearbox, it is advisable to check the slipping torque. See the corresponding Maintenance Manual (Line Maintenance) for the respective engine type, 912 Series or 914 Series. ■ CAUTION : When removing the gearbox, take care not to damage the bearing seat and the oil seal running surface of the propeller shaft.
  • Page 91 BRP-Rotax Maintenance Manual Fig. 72-20 00244 Fig. 72-21 00247 72-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 23 May 01/2007...

  • Page 92: 3) Removal Of Roller Bearing For - Series 4

    BRP-Rotax Maintenance Manual 3.9.1) Removal of roller bearing for - Series 2 See Fig. 72-22. After the propeller gearbox is removed, the crankcase side propeller shaft bearing and oil seal can be replaced if necessary. Remove the retaining ring (1) with the circlip pliers. Screw extractor (2) part no.
  • Page 93 BRP-Rotax Maintenance Manual Fig. 72-22 00248 72-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 25 May 01/2007...
  • Page 94 Before disassembly, the governor flange must be removed. On configuration 912 Series 3 with hydraulic governor, the procedure for pressing out varies from that for Series 2 and 4. On Series 3, the roller bearing is pressed out together with the oil inlet flange.
  • Page 95 BRP-Rotax Maintenance Manual 3.9.3) Removal of roller bearing for - Series 4 See Fig. 72-24. After the propeller gearbox is removed, the crankcase side propeller shaft bearing can be replaced if necessary. For the extracting procedure it is necessary to drill a bore (2) of at least 6.2 mm dia., (1/4") into the center of the oil inlet cover (1).

  • Page 96: 4) Propeller Gearbox Disassembly

    (8) 80x35x3, step collar (9), 6 mm (0.236 in.) distance sleeve (17), compensating shim (10), eccenter (11) (for fuel pump on the ROTAX 912 Series, of no significance on the 914 Series) and 8 mm (0.31in.) distance sleeve (12). ■ CAUTION:...
  • Page 97 BRP-Rotax Maintenance Manual Fig. 72-27 Dog hub 07704 Overload clutch 72-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 29 May 01/2007...

  • Page 98: 5) Propeller Shaft Removal

    BRP-Rotax Maintenance Manual 3.9.5) Propeller shaft removal See Figs. 72-28 and 72-29. Place gearbox housing on a suitable surface and press out the propeller shaft with a hand press. Alternatively, the extractor (1), part no. 877615, can be used to press out the propeller shaft.
  • Page 99 BRP-Rotax Maintenance Manual Fig. 72-28 Fig. 72-29 00263 00264 72-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 31 May 01/2007...

  • Page 100: 6) Vacuum Pump Drive Removal

    BRP-Rotax Maintenance Manual 3.9.6) Vacuum pump drive removal See Fig. 72-30. The vacuum pump is driven via the drive gear (1) fitted on the propeller shaft. Check the ball bearing (2) and the needle sleeve (3). Check the gear- tooth system of drive gear (1), the vacuum pump gear (4), the drive sleeve (5) and the drive shaft of the vacuum pump.

  • Page 101: 7) Propeller Governor Drive Removal

    BRP-Rotax Maintenance Manual 3.9.7) Propeller governor drive removal See Figs. 72-31 and 72-32. Remove banjo bolts (1) M10x1 and both sealing rings (2) from the governor flange (3) and the oil pump housing and remove the oil line. Remove the 4 allen screws (4) M6x20 and 2 allen screws (5) M6x16 for oil inlet flange fixation.
  • Page 102 BRP-Rotax Maintenance Manual Fig. 72-32 00257 Measure the inner diameter (13) of the propeller shaft and the bearing neck (14) of the oil inlet flange. The wear will probably appear as a flat area on the journal. Check the gear-tooth system of the drive gear (15) and the vacuum pump gear (8).
  • Page 103 BRP-Rotax Maintenance Manual 3.9.8) Propeller governor drive installation See Figs. 72-33 and 72-34. ■ CAUTION : The oil inlet flange must be fitted well aligned and the O-ring must not be squeezed. Install needle sleeve and ball bearing as described in 72-00-00 sec.
  • Page 104 BRP-Rotax Maintenance Manual ■ CAUTION : Longer screws will damage the oil inlet flange. ◆ NOTE: Tightening torque 10 Nm (90 in.lb). The allen screws (12) and (13) are secured with LOCTITE 221. Fit the governor (14) and the new gasket (15). Take care that the gear- tooth system engages.
  • Page 105 BRP-Rotax Maintenance Manual Fig. 72-34 00259 72-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 37 May 01/2007...

  • Page 106: 9) Vacuum Pump Drive Installation

    BRP-Rotax Maintenance Manual 3.9.9) Vacuum pump drive installation See Figs. 72-34, 72-35 and 72-36. Lubricate new needle sleeve (3). Position puller cap (10), part no. 876489, on gearbox side, place press-in insert, part no. 877579, (11) onto the needle sleeve and fix with the hex. nut (12). Turning the hex.

  • Page 107: 10) Gearbox Components Inspection

    BRP-Rotax Maintenance Manual 3.9.10) Gearbox components inspection See Figs. 72-37, 72-38, 72-39, 72-40, 72-41 and 72-42. Clean disassembled gearbox with suitable cleaning agents and check the following parts: — Check that the bearing bushing (1) for crankshaft support bearing in the gear cover fits tightly and measure dimension (GB01).
  • Page 108 BRP-Rotax Maintenance Manual Treatment of corrosion damage and surface damage to the propeller flange The flange of the propeller shaft is subject to corrosion. After wrapping the propeller shaft (2) in plastic tape or covering it with plastic tubing, the propeller flange can be treated with an abrasive.
  • Page 109 BRP-Rotax Maintenance Manual — Carry out a visual inspection of the dog gear (11) and the dog hub (12) to establish whether pitting is visible on the gear-tooth system and/or the sliding ramps (GB08) of the dogs. Ensure that the ramp tops of the dog gear are clearing the ramp valleys of the dog hub.
  • Page 110 BRP-Rotax Maintenance Manual Fig. 72-41 00269 — Carry out a visual inspection of the ring halves (17) and replace if necessary. — If there is visible wear to the disc springs (18) in the contact area (19), they must be replaced. Check dimension (GB13) of the uncompressed disc spring.

  • Page 111: 11) Toothed Shaft Profiles Inspection

    BRP-Rotax Maintenance Manual 3.9.11) Toothed shaft profiles inspection See Fig. 72-43. There are two important toothed shaft connections in the gearbox. – crankshaft to drive gear – propeller shaft to clutch hub of the overload clutch Carry out a visual inspection of all toothed shaft profiles for damage and wear.

  • Page 112: 12) Gear Set (Gear Wheels) Inspection

    BRP-Rotax Maintenance Manual 3.9.12) Gear set (gear wheels) inspection The gear set is inspected to detect any damage to the gear-tooth system. ◆ NOTE: The gear set can be inspected with the gearbox installed by using an endoscope. This must be done in such a way that the condition of the gear flanks can be precisely evaluated.
  • Page 113 If you are in any doubt, seek assistance by studying technical publications or consult your au- thorized ROTAX distributor or Service Center. 72-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0...
  • Page 114 BRP-Rotax Maintenance Manual 00148 Fig. 72-44 Magn.: approx. 100% 00149 Fig. 72-45 Magn.: approx. 75% 00150 Fig. 72-46 Magn.: approx. 75% 72-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 46 May 01/2007...
  • Page 115 BRP-Rotax Maintenance Manual Advanced pitting: See Figs. 72-47 and 72-48. Characteristics: Larger areas of breakoff, normally appearing as pitting zones. The breakoff surface usually has a shelllike structure. The total pitting zone may reach a size where it impairs smooth engine running noticeably or the remaining flank surface wears rapidly and is destroyed.
  • Page 116 BRP-Rotax Maintenance Manual Spallation (large zones of the tooth flank have broken off) See Figs. 72-49 and 72-50. Characteristics: Large triangular areas of the tooth flank have broken off, starting in a grey zone or area of minor pitting on the root of the tooth. The spalling area is of relatively constant depth.

  • Page 117: 13) Propeller Gearbox Reassembly

    BRP-Rotax Maintenance Manual 3.9.13) Propeller gearbox reassembly See Figs. 72-51, 72-52 and 72-53. Heat gearbox housing (1) with hot air (or in an oven) to approx 100 ° (212 °F). Press shaft seal (2) into the gearbox housing from the inside, using insertion jig, part no.
  • Page 118 BRP-Rotax Maintenance Manual ■ CAUTION : If the disc springs are not well centered, the dog gear cannot be depressed sufficiently to allow insertion of ring halves. Do not increase the pressure, but remove the clutch again and center the disc springs more accurately.

  • Page 119: 14) Disc Spring Pre-Tension Adjustment

    BRP-Rotax Maintenance Manual 3.9.14) Disc spring pre-tension adjustment See Figs. 72-53 and 72-25 (see Section 72-00-00 / 3.9.4). When the propeller shaft assembly is uncompressed, the contact surface (24) for the ring halves must lie in the groove of the propeller shaft 1 mm (0.039 in.) over the upper edge (25).
  • Page 120 BRP-Rotax Maintenance Manual Fig. 72-53 Version with Version with dog hub overload clutch 22 21 08208 72-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 52 May 01/2007...

  • Page 121: 15) Propeller Gearbox - Installation

    BRP-Rotax Maintenance Manual 3.9.15) Propeller gearbox — installation See Figs. 72-54, 72-55 and 72-56. Carry out a visual inspection of the crankshaft (1) on the power take off side. Slide drive gear (2) onto the crankshaft (3). Apply LOCTITE 648 to hex.
  • Page 122 BRP-Rotax Maintenance Manual Position gearbox housing with completely pre-assembled gear unit, previously coated with sealing compound LOCTITE 574. Turn propeller shaft slightly to allow the dog gear to engage. By gently tapping on the gearbox housing (not on the propeller shaft) with a plastic mallet, the gearbox is fitted on the crankcase.

  • Page 123: Cylinder Head - Removal

    BRP-Rotax Maintenance Manual 3.10) Cylinder head — removal See Figs. 72-57 and 72-58. If components of several cylinders are disassembled, they must be marked to ensure correct coordination at refitting. Remove allen screw M6x25 (1) and washer from valve cover (2) and lift off valve cover and large and small O-ring.
  • Page 124 BRP-Rotax Maintenance Manual Keep both push rods (6) in position in the oil return tubes (7), seal oil bore of push rods with finger and remove cylinder head (8). The oil return tubes remain with the cylinder head. Remove O-rings (9) 16x15 from the oil return tubes or from the crankcase (10).

  • Page 125: Cylinder Head - Disassembly

    BRP-Rotax Maintenance Manual 3.11) Cylinder head - disassembly See Fig. 72-59. If the rocker arms are to be dismantled without removing the cylinder head, turn the crankshaft to set the piston of the respective cylinder to ignition T.D.C. so that only little pressure remains on the rocker arm. Depress rocker arm with check lever part no.
  • Page 126 In the event of more serious leakage, cylinder and cylinder head can be reworked as described in the Overhaul Manual by a ROTAX authorized overhaul facility. If the engine has been "run hot", the hardness of the cylinder head and the cylinder material must be checked.

  • Page 127: 1) Cylinder Head And Studs

    See the corresponding Maintenance Manual (Line Maintenance) for the re- spective engine type, 912 Series or 914 Series. Hard- ness is tested at control point CH08 as shown in Fig. 72- Procedure for hardness test: CH08: HB2.5/62.5 DIN EN ISO 6506-2...
  • Page 128 BRP-Rotax Maintenance Manual ◆ NOTE: If the rocker arm shaft bearing (CH05) is worn, it can be reworked up to a certain limit. The cylinder head must be sent to an authorized overhaul facility for this purpose. Fig. 72-62 07831...

  • Page 129: 2) Reworking Of The Sealing Surface To The Exhaust Manifold

    BRP-Rotax Maintenance Manual 3.11.2) Reworking of the sealing surface to the exhaust manifold See Fig. 72-63. Reworking is permissible if there is a leak at the sealing surface (1) to the exhaust manifold. The diameter of the sealing surface must not be increased to more than dimension CH09.

  • Page 130: 3) Valve Guides

    Check diameter of valve stem (1) and inner diameter of valve guide (2), see dimension (VT01) and dimension (CH01). If wear limit is reached, replace valve guide. See 72-00-00 sec. 4. For this procedure, the cylinder head must be sent to a ROTAX authorized overhaul facility for maintenance. Fig. 72-65 Fig. 72-64 CH01 Maß...

  • Page 131: 4) Valve Seats

    The width of the imprint corresponds to the width of the valve seat CH02. ■ CAUTION: If burned spots or deformation are detected, send the cylinder head to a ROTAX authorized overhaul facility for overhaul. See 72-00-00 sec. 4. 00285 45°...

  • Page 132: 5) Valves

    BRP-Rotax Maintenance Manual 3.11.5) Valves See Figs. 72-67, 72-68, 72-69 and 72-70. Intake valves are checked as follows: Carry out a visual inspection of the valves for damage and wear. Clean valves, measure valve stem diameter and check valve disk for wear.
  • Page 133 BRP-Rotax Maintenance Manual Oil carbon residue on up to max 20% of the moving path is permissible. See Fig. 72-67. ■ CAUTION: If there are heavier deposits, the valve may already have overheated and must be replaced. There is a danger of valve fracture at the weld.
  • Page 134 BRP-Rotax Maintenance Manual Check the valve face for wear caused by pounding VT03. Pounding may occur on the inside and the outside edge of the seat surface and must be measured as shown in Fig. 72-68. See 72-00-00 sec. 4.

  • Page 135: 6) Valve Springs

    BRP-Rotax Maintenance Manual 3.11.6) Valve springs See Figs. 72-71 and 72-72. Carry out a visual inspection of the valve springs for damage and wear. Depending on engine version, dual or single valve spring configurations are planned. However, dual and single valve springs must not be used on the same engine.
  • Page 136 BRP-Rotax Maintenance Manual To check the spring force, apply a test load (F) (test weight set assy. part no. 976995) and measure the remaining spring length VT04 (measuring fixture part no. 976210). See Fig. 72-72. Test load for dual valve spring configuration: –...

  • Page 137: 7) Washers

    BRP-Rotax Maintenance Manual 3.11.7) Washers See Figs. 72-73, 72-74 and 72-75. Carry out a visual inspection of the washers for damage and wear. The wear must be measured radially with a dial gauge, starting from the reference area (on the inner part of the valve spring support) in measuring range radius (1) and working towards the outside.

  • Page 138: 8) Rocker Arm And Rocker Arm Shaft

    BRP-Rotax Maintenance Manual 3.11.8) Rocker arm and rocker arm shaft See Figs. 72-76 and 72-77. The rocker arm bearing (1) is lubricated via the hollow pushrod (2) to the ball joint (female) (3). The oil flows through the oil ducts (4) in the rocker arm to lubricate the rocker arm bearing.

  • Page 139: 1) Rocker Arm With Plastic Bushing

    BRP-Rotax Maintenance Manual 3.11.8.1) Rocker arm with plastic bushing See Figs. 72-78, 72-79 and 72-80. In the case of plastic rocker arm bushings (2), it must be ensured that the bushing is of slide fit design. After installa- tion, it must still be possible to rotate it against the rocker arm bore.

  • Page 140: 2) Rocker Arm With Pressed Sinter Bushing

    BRP-Rotax Maintenance Manual 3.11.8.2) Rocker arm with pressed sinter bushing See Fig. 72-81. See 72-00-00 sec. 4. The bearing bush cannot be replaced. If the rocker arm is worn, it must be replaced with a rocker arm with a plastic bushing.

  • Page 141: Cylinder Head Reassembly

    BRP-Rotax Maintenance Manual 3.12) Cylinder head reassembly See Fig. 72-83. Place valve spring support (1) in position on the valve guide and fit new valve stem seal (2) on inlet side only. Push oiled intake valve (3) into the valve guide from the outside, slide on both valve springs (outside (4) and inside (5)) or single valve spring (17) and the valve spring retainer (6).
  • Page 142 BRP-Rotax Maintenance Manual Fig. 72-83 07707 72-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 74 May 01/2007...

  • Page 143: Cylinder And Piston - Removal

    BRP-Rotax Maintenance Manual 3.13) Cylinder and piston - removal See Figs. 72-84 and 72-85. ◆ NOTE: Prior to removal, mark cylinders and pistons in pairs to ensure correct coordination on re-assembly. The cylinders are all identical in design. The piston pin center is offset from piston center.
  • Page 144 BRP-Rotax Maintenance Manual Push out piston pin using installation tool, part no. 877016. If the piston pin is fitted too tightly, it can be pulled out using the piston pin extraction tool (4), part no. 877090, see 00-00-00 sec. 10.6. Insert the pullout spindle (5) into the piston pin (6) and screw on the nut (7).

  • Page 145: 1) Checking Pistons

    BRP-Rotax Maintenance Manual 3.13.1) Checking pistons See Figs. 72-86 and 72-87. On engines of the 912/914 Series, light alloy full skirt cast pistons are used. The piston axis is offset by 1 mm (0.039 in.). Remove piston rings using a pair of piston ring pliers. Make absolutely sure to re-fit rings in their initial position.
  • Page 146 BRP-Rotax Maintenance Manual Fig. 72-86 PI02 PI02 PI01 13mm (0.51 in) 07435 Fig. 72-87 Pl04 Pl05 Pl06 07412 72-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 78 May 01/2007...

  • Page 147: 2) Checking The Piston Ring

    BRP-Rotax Maintenance Manual 3.13.2) Checking the piston ring See Figs. 72-88 and 72-89. Check the end clearance of the cleaned piston rings. To determine the end clearance (4), remove the piston rings from the piston using piston ring pliers, clean them and insert into the cylinder.

  • Page 148: 3) Piston Pin

    BRP-Rotax Maintenance Manual 3.13.3) Piston pin See Fig. 72-90 Measure piston pin and check for traces of seizure in area of con-rod seat. In case of distinct traces of seizure, replace piston pin even if dimensions are correct. Measure dimension PI03.

  • Page 149: 4) Cylinders Inspection

    BRP-Rotax Maintenance Manual 3.13.4) Cylinders inspection See Figs. 72-91, 72-92 and 72-93. The running surface of the cylinder is "NICKEL-SILICON"coated. All 4 cylinders are identical. Clean the cooling fins (1) of the cylinder. Remove oil carbon deposits from the top end (2) of the cylinder bore.
  • Page 150 BRP-Rotax Maintenance Manual Fig. 72-91 00297 Fig. 72-92 Fig. 72-93 CY03 (0.197 in.) CY04 40mm CY01 (1.57 in.) CY02 76mm (2.99 in.) 07485 07413 72-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 82 May 01/2007...

  • Page 151: Hydraulic Valve Tappets

    ■ CAUTION : If it is necessary to replace a hydraulic valve tappet, make sure that a tappet with a polished cam running surface (ROTAX part no. 881831) is used. Depending on storage conditions, new hydraulic valve tappets are partially emptied and pump full of oil during engine startup.
  • Page 152 BRP-Rotax Maintenance Manual Fig. 72-94 00299 Fig. 72-96 Fig. 72-95 00301 00300 Fig. 72-97 VT10 07541 72-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 84 May 01/2007...

  • Page 153: Pushrods

    BRP-Rotax Maintenance Manual 3.15) Pushrods See Fig. 72-98. Clean push-rods (1) and carry out a visual inspection. Make sure that the two ball heads (2) pressed into the rod fit tightly. Excessive engine speed may have caused bending of the pushrods. Roll push-rods and check for run out, dimension (VT09).

  • Page 154: Piston And Cylinder Assembly Fitting

    BRP-Rotax Maintenance Manual 3.16) Piston and cylinder assembly fitting 3.16.1) Hydraulic valve tappets fitting Lubricate bearing bore for hydraulic valve tappets in crankcase. Apply LOCTITE Anti-Seize to the contact surfaces of the hydraulic valve tappets, lubricate their circumference and insert them into the crank- case according to the recorded position .
  • Page 155 BRP-Rotax Maintenance Manual Fig. 72-101 Zylinder 1 und 3 / Zylinder 2 und 4 / auf den Propellerflansch gesehen / Cylinder 1 and 3 Cylinder 2 and 4 looking at propeller flange 00305 Oil the entire length of the piston pin (4). The connecting rod eye (5) and the piston pin bore (6) are also oiled.
  • Page 156 BRP-Rotax Maintenance Manual ■ CAUTION: Always use new mono hook circlips! Used retaining rings or retaining rings which have already been fitted have too little tangential tension, can twist and thus wear the groove in the piston. Fit piston pin circlip with installation tool, part no. 877802. To do so, press the mono hook circlip (11) into the groove (14) of the mounting sleeve (13) and push guide punch (12) into the mounting sleeve.
  • Page 157 BRP-Rotax Maintenance Manual Fig. 72-104 02038 Fig. 72-105 (0.166 in) (0.079 in) 4,2 mm 2 mm 08206 72-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 89 May 01/2007...

  • Page 158: 3) Cylinders Fitting

    BRP-Rotax Maintenance Manual 3.16.3) Cylinders fitting See Fig. 72-106. Place O-ring 87x2 on the cylinder skirt and oil the cylinder wall. ◆ NOTE: On engines with crankcases bearing serial numbers up to S/N 27811, there is an O-ring 87x2 fitted to depress stud bolt M8x297.
  • Page 159 BRP-Rotax Maintenance Manual ° - 3 0 ° Fig. 72-106 ° - 3 0 ° 05766 72-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 91 May 01/2007...

  • Page 160: 4) Cylinder Head Fitting

    BRP-Rotax Maintenance Manual 3.16.4) Cylinder head fitting See Figs. 72-107, 72-108, 72-109 and 72-110. Install respective pushrods (1) in both oil return tubes on the pre- assembled cylinder head and place pre-oiled O-ring (2) 16x5 on oil return tube (3).
  • Page 161 BRP-Rotax Maintenance Manual Lubricate all moving parts in rocker arm compartment. Place O-ring (13) 105x2.5 and O-ring (14) 6.4x1.8 in the valve cover (15). Fit valve cover and tighten with allen screw (16) M6x30 and washer (17) to a tightening torque of 10 Nm (90 in.lb).
  • Page 162 BRP-Rotax Maintenance Manual Fig. 72-108 07709 Fig. 72-109 08340 Fig. 72-110 00312 72-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 94 May 01/2007...

  • Page 163: Intake Manifold And Compensation Tube Assembly

    BRP-Rotax Maintenance Manual 3.17) Intake manifold and compensation tube assembly See Fig. 72-111 Attach compensation tube (1) and the resonator hoses (2) on both ends with screw hose clamps (3). The spring which supports the carburetor hooks into the bracket (4). See 73-00-00 sec. 3.5.
  • Page 164 BRP-Rotax Maintenance Manual NOTES 72-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 96 May 01/2007...

  • Page 165: Wear Limits

    BRP-Rotax Maintenance Manual 4) Wear limits Kurbelwelle (crankshaft) CS04 CS05 07710 CS07 Kurbelwelle (crankshaft) 07507 07517 72-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 97 May 01/2007...
  • Page 166 BRP-Rotax Maintenance Manual wear wear 07200 Reading new limit limit Description Readings 100% Crankshaft Journal at actual 27,99 28,00 27,95 27,97 power take (S1) CS04 1,1020 1,1024 1,1004 1,1012 renewed off end Journal at actual 31,99 32,00 31,95 31,97 magneto...
  • Page 167 BRP-Rotax Maintenance Manual PI02 PI02 PI01 13mm (0.51 in.) 07435 PI03 07403 72-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 99 May 01/2007...
  • Page 168 BRP-Rotax Maintenance Manual Pl04 Pl05 Pl06 07412 07432 PI07 / PI08 / PI09 72-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 100 May 01/2007...
  • Page 169 BRP-Rotax Maintenance Manual wear wear 07221 Reading new limit limit Description Readings 100% Piston Cyl. 1 Cyl. 2 Cyl. 3 Cyl. 4 actual Piston red 79,488 79,502 79,390 79,439 PI01 79,5 mm / 3,1 in. 3,1294 3,1300 3,1256 3,1275 renewed...
  • Page 170 BRP-Rotax Maintenance Manual wear wear 07221 Reading new limit limit Description Readings 100% Piston Cyl. 1 Cyl. 2 Cyl. 3 Cyl. 4 actual Pison pin clearance PI02/ 0,006 0,013 0,050 0,032 in piston pin bore PI03 0,0002 0,0005 0,0020 0,0012...
  • Page 171 BRP-Rotax Maintenance Manual CY03 (0.197 in.) 40mm CY01 (1.57 in.) 76mm CY02 (2.99 in.) 07485 CH01 07831 07427 72-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 103 May 01/2007...
  • Page 172 BRP-Rotax Maintenance Manual 3 mm (0.12 in.) 3 mm (0.12 in.) 07443 max 20% VT02 07482 ~45 mm ~25 mm (1.77 in.) (0.98 in.) 07425 07483 72-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 104 May 01/2007...
  • Page 173 BRP-Rotax Maintenance Manual 07498 07496 VT06 07497 VT08 07409 VT07 07417 ~160 mm (6.30 in.) 72-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 105 May 01/2007...
  • Page 174 BRP-Rotax Maintenance Manual 07541 VT10 08207 07488 72-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 106 May 01/2007...
  • Page 175 BRP-Rotax Maintenance Manual wear wear 07222 Reading new limit limit Description Readings 100% Cylinder Cyl. 1 Cyl. 2 Cyl. 3 Cyl. 4 actual 79,500 79,512 79,580 79,546 (D1) CY01 3,1299 3,1304 3,1331 3,1317 renewed CY01 +0,015/-0,008 actual Cylinder- CY01 +0,015...

  • Page 176: Cylinder Head

    BRP-Rotax Maintenance Manual wear wear 07223 Reading new limit limit Description Readings 100% Cylinder head Cyl. 1 Cyl. 2 Cyl. 3 Cyl. 4 actual 7,006 7,018 7,150 7,084 Int. V. CH01 0,2758 0,2763 0,2815 0,2789 Valve guide renewed bore inner...
  • Page 177 BRP-Rotax Maintenance Manual wear wear 07223 Reading new limit limit Description Readings 100% Cylinder head Cyl. 1 Cyl. 2 Cyl. 3 Cyl. 4 actual Int. V. VT03 0,000 0,000 0,008 0,004 renewed Wear on valve head actual Exh. V. VT03...
  • Page 178 BRP-Rotax Maintenance Manual wear wear 07223 Reading new limit limit Description Readings 100% Cylinder head Cyl. 1 Cyl. 2 Cyl. 3 Cyl. 4 actual 12,183 12,194 12,150 12,167 Int. V. VT05 0,4796 0,4801 0,4783 0,4790 Rocker arm renewed shaft "over- actual size"...
  • Page 179 BRP-Rotax Maintenance Manual wear wear 07223 Reading new limit limit Description Readings 100% Cylinder head Cyl. 1 Cyl. 2 Cyl. 3 Cyl. 4 actual 0,000 0,100 0,200 0,150 Int. V. VT09 0,0000 0,0039 0,0079 0,0059 renewed Push rod deflection actual...
  • Page 180 BRP-Rotax Maintenance Manual GB04 07453 GB01 07452 GB08 GB11 Ausführung 3 07454 GB07 07420 07436 GB13 07471 72-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 112 May 01/2007...
  • Page 181 BRP-Rotax Maintenance Manual GB18 07456 07508 07506 72-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 113 May 01/2007...
  • Page 182 BRP-Rotax Maintenance Manual wear wear 07224 Reading new limit limit Description Readings 100% Propeller gear box 1) Bearing bush in gear cover actual 28,03 28,04 28,10 28,07 Bore GB01 1,1035 1,1039 1,1063 1,1051 renewed actual GB01/ 0,03 0,05 0,12 0,09...
  • Page 183 BRP-Rotax Maintenance Manual wear wear Reading new 07224 limit limit Description Readings 100% 4) Tooth profile actual 0,95 1,00 0,80 0,88 Crankshaft CS07 0,0374 0,0374 0,0315 0,0344 renewed actual 0,95 1,00 0,80 0,88 Drive gear GB14 0,0374 0,0374 0,0315 0,0344...
  • Page 184 BRP-Rotax Maintenance Manual NOTES 72-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 116 May 01/2007...

  • Page 185: Form Sheets

    BRP-Rotax Maintenance Manual 5) Form Sheets 5.1) Form sheet for material testing ROTAX 912/914 Series 5.1.1) Inspection on cracks 5.1.2) Hardness test 07207 Findings Description Remarks Checked Flywheel hub Propeller shaft dog gear dog hub drive gear CY04 CH08 07413...
  • Page 186 BRP-Rotax Maintenance Manual NOTES 72-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 118 May 01/2007...
  • Page 187 3.3.1) General note ................. 73-00-00 / 21 3.3.2) Float needle valve leakage test ........... 73-00-00 / 22 3.3.3) Individual components of the carburetor (on the 912 Series)73-00-00 / 23 3.3.4) Individual components of the carburetor (on the 914 Series)73-00-00 / 24 3.3.5) Diaphragm ................
  • Page 188 3.3.15) Throttle cable and linkage ............. 73-00-00 / 33 3.4) General information on the fuel system ........73-00-00 / 34 3.4.1) Fuel pressure (on 912 Series) ..........73-00-00 / 35 3.4.2) Fuel pressure (on 914 Series) ..........73-00-00 / 37 3.4.3) Carburetor sockets ...............

  • Page 189: Systems Description

    BRP-Rotax Maintenance Manual 2) Systems description 2.1) Fuel system (on 912 Series) See Fig. 73-1. The fuel system comprises the following items: fuel tank coarse filter fine filter water drain cock fire cock 1 mechanical fuel pump 2 carburetors and the required fuel piping and connections The fuel passes from the tank (1) with the coarse filter (2) via the fire cock (3), the water drain cock (4) and the fine filter (5) to the mechanical fuel pump (6).
  • Page 190 (1) inlet from the tank (2) coarse filter (3) fire cock (4) water drain cock (5) fine filter (6) mechanical fuel pump (7) carburetors (8) return line to tank 73-00-00 Effectivity 912 Series Edition 1 / Rev. 0 page 4 May 01/2007...

  • Page 191: Fuel System (On 914 Series)

    BRP-Rotax Maintenance Manual 2.2) Fuel system (on 914 Series) See Fig. 73-2. The fuel system comprises the following items: fuel tank coarse filter fine filter / water trap fire cock 2 electric fuel pumps 2 check valves and the required fuel piping and connections...
  • Page 192 BRP-Rotax Maintenance Manual Fig. 73-2 MAIN 00103 Legend: (1) fine filter / water trap (2) main fuel pump (MAIN) (3) auxiliary fuel pump (AUX) (4) check valve (5) fuel pressure regulator (6) inlet from the tank (7) return line to tank...

  • Page 193: Fuel Filter

    The built-in filter on the suction side of the electric fuel pumps cannot not be replaced. 2.4) Fuel pump (on 912 Series) The engines of the 912 Series are equipped with a mechanical fuel pump. It is driven via an eccenter in the propeller gearbox. 2.5) Fuel pump (on 914 Series) To warrant safe and adequate operation of the fuel system, two independent selfpriming vane pumps are used.

  • Page 194: Fuel Pressure Regulator (Only On 914 Series)

    BRP-Rotax Maintenance Manual 2.6) Fuel pressure regulator (only on 914 Series) See Figs. 73-3 and 73-4. The fuel pressure regulator (1) is mounted on the airbox. Fuel pressure control is essential for flawless engine operation because it keeps the fuel pressure permanently at approx. 0.25 bar (3.6 p.s.i.) above the varying boost pressure in the airbox.
  • Page 195 BRP-Rotax Maintenance Manual Part of the fuel flow from the pumps (approx. 100 l/h) is routed back to the fuel tank via the diaphragm controlled cone valve (8), thus establishing a pressure 0.25 bar (3.6 p.s.i.) higher in the top chamber (fuel side) than in the lower chamber (air side).

  • Page 196: Pressure Connecting Lines (Only On 914 Series)

    BRP-Rotax Maintenance Manual 2.7) Pressure connecting lines (only on 914 Series) See Fig. 73-5. The engines of the 912/914 Series are equipped with constant depression carburetors. For the operation of the carburetors it is necessary that a) the atmospheric pressure in the float chamber corresponds with...
  • Page 197 BRP-Rotax Maintenance Manual The purpose of enriching the mixture is to reduce the thermal load on the engine during the shorter takeoff phase and to provide added protection against knocking combustion (detonation). ▲ WARNING: The pressure connecting lines must function properly to ensure correct engine running.

  • Page 198: Bing Constant Depression Carburetor Type 64-3

    BRP-Rotax Maintenance Manual 2.8) BING constant depression carburetor type 64-3 See Figs. 73-6, 73-7 and 73-8. The BING constant depression carburetor type 64-3 is a cross-draft butterfly valve carburetor with variable venturi, double float system arranged centrally below the venturi, and a rotary disc valve type starting carburetor. Its particular feature is the carburetor piston (2), which is suspended on a rubber diaphragm (3) and protrudes into the venturi.
  • Page 199 BRP-Rotax Maintenance Manual On its way from the float chamber to the venturi, the fuel passes through the main jet (7), the mixing tube and the needle jet and in the diffuser tube (8) is pre- mixed with air which is brought in from the air filter via the air duct (9) and the atomizer in an annular flow around the needle jet.
  • Page 200 BRP-Rotax Maintenance Manual During idling and low-load operation of the engine, the throttle valve is closed to such an extent that the airflow underneath the carburetor piston (2) no longer forms a sufficient vacuum. The supply of fuel to the intake air is then effected via the idling system, which consists of the idle jet (5) and the idling air jet (6).

  • Page 201: Handling Of Fuel

    BRP-Rotax Maintenance Manual 2.9) Handling of fuel Use only clean gasoline of a registered brand. Unleaded fuels contain alcohol. Alcohol binds up to 50 % of its own volume in water. Water enters the system mainly in the form of condensation. For this reason, avoid extreme differences in temperature, long period storage, direct sun and plastic containers.

  • Page 202: Connections For Instrumentation

    ◆ NOTE: An airbox with a carburetor preheating flap is available for engines of the 912 Series. ◆ NOTE: Engines of the 914 Series normally do not require any preheating device as the intake air is preheated by the turbocharger.

  • Page 203: Maintenance

    Models produced from the year 2007 onwards have a flexible fuel line (2). If the engine is equipped with a ROTAX Original Airbox, the screw hose clamps (1) must be released before the carburetors can be removed. Remove the fuel line (2) by unscrewing the collar nut (3).
  • Page 204 BRP-Rotax Maintenance Manual Fig. 73-9 07711 73-00-00 Effectivity 912 Series Edition 1 / Rev. 0 page 18 May 01/2007...
  • Page 205 BRP-Rotax Maintenance Manual 3.2) Disassembling carburetors, carburetor sockets, fuel lines and drip tray (on the 914 Series) See Figs. 73-10 and 73-11. To remove the carburetors, loosen the screw hose clamps (3). Remove the fuel line (4) by removing banjo bolts M10 (5) with sealing rings (6).
  • Page 206 BRP-Rotax Maintenance Manual Fig. 73-10 07712 Fig. 73-11 A Loctite 221 07713 73-00-00 Effectivity 914 Series Edition 1 / Rev. 0 page 20 May 01/2007...

  • Page 207: Bing-Constant Depression Carburetor Inspection

    (1000 ft) above Mean Sea Level. Only aeronautical personnel or authorized testers act- ing on our instructions may carry out modifications to BRP-Rotax specifications. ■ CAUTION: To avoid contamination in the fuel system, proceed with great care and cleanliness. It is essential to store carburetors and dismantled parts on clean surfaces.

  • Page 208: 2) Float Needle Valve Leakage Test

    BRP-Rotax Maintenance Manual 3.3.2) Float needle valve leakage test See Fig. 73-12. This check is carried out to ensure that the float valve seat is not leaking. If the pressure is not maintained, pay particular attention during disassembly to the float valve with the viton tip and the carburetor housing.

  • Page 209: 3) Individual Components Of The Carburetor (On The 912 Series)73-00-00

    BRP-Rotax Maintenance Manual 3.3.3) Individual components of the carburetor (on the 912 Series) See Illustrated Parts Catalog Rotax 912/914 Fig. 73-13 07088 73-00-00 Effectivity 912 Series Edition 1 / Rev. 0 page 23 May 01/2007...

  • Page 210: 4) Individual Components Of The Carburetor (On The 914 Series)73-00-00

    BRP-Rotax Maintenance Manual 3.3.4) Individual components of the carburetor (on the 914 Series) See Illustrated Parts Catalog Rotax 912/914 Fig. 73-14 l . ( l . ) l . ( l . ) 07087 73-00-00 Effectivity 914 Series Edition 1 / Rev. 0...

  • Page 211: 5) Diaphragm

    BRP-Rotax Maintenance Manual 3.3.5) Diaphragm See Figs. 73-15 and 73-16. The plunger (carburetor piston) (8) is attached to the diaphragm (6). Depending on the pressure prevailing, the plunger is moved up or down. For inspection, remove the two counter sunk screws (1) M5x12, take off the chamber top (2) and remove the plunger spring (3).
  • Page 212 BRP-Rotax Maintenance Manual Fig. 73-15 Fig. 73-16 07229 07230 73-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 26 May 01/2007...

  • Page 213: 7) Float Chamber, Floats

    3.3.7) Float chamber, floats See Figs. 73-17, 73-18, 73-19 and 73-20. On the 912 Series: Release the spring clip (39). See Fig. 73-13. On the 914 Series: Remove the safety wiring and the end screw (1) with the sealing ring (2) 16x22x1. Tightening torque 5.5 Nm (48.7 in.lb)

  • Page 214: 8) Float Brackets

    (14). When the needle valve is closed, the two arms (15) of the float bracket must be evenly spaced. Spacing: On the 912 Series: 0.4 to 0.5 mm (.016 to .02 in.) On the 914 Series: 5.4 to 5.5 mm (.21 to .22 in.) Always replace float brackets together with the float needle valve.

  • Page 215: 9) Carburetor Jets

    Check for correct jetting. See corresponding Illustrated Parts Catalog. ▲ WARNING: Any adjustments to the main jets may only be per- formed in accordance with BRP-Rotax instructions, by an aviation facility or an authorized tester. Fig. 73-21 Fig. 73-22...

  • Page 216: 10) Float Needle Valve Inspection

    BRP-Rotax Maintenance Manual 3.3.10) Float needle valve inspection See Fig. 73-23, 73-24. Remove the float chamber. Remove the bearing pin (4) of the float bracket (5) and pull out the float needle. Check fuel inlet for free passage. Inspect the viton tip (1). Inspect clip end for visible wear to the beaded edge (2) of the sprung pin (3), the valve must be replaced.

  • Page 217: 11) Starting Carburetor (Choke)

    BRP-Rotax Maintenance Manual 3.3.11) Starting carburetor (choke) See Figs. 73-25, 73-26 and 73-27. Remove 4 countersunk screws M4x14 and remove the complete rotary disc valve housing. ◆ NOTE: The shafts for the rotary disc valve have two markings, L and R. The shaft marked R is for the carburetors for cylinders 2/4, the shaft marked L for the carburetor for cylinders 1/3.
  • Page 218 BRP-Rotax Maintenance Manual the drawings show the carburetor for cyl. 2/4 Fig. 73-26 00362 Fig. 73-27 00363 73-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 32 May 01/2007...

  • Page 219: 13) Carburetor Synchronization

    Maintenance Manual 3.3.13) Carburetor synchronization See the corresponding section in the respective Maintenance Manual (Line Maintenance) for the engine type, 912 Series or 914 Series. 3.3.14) Idle speed adjustment See the corresponding section in the respective Maintenance Manual (Line Maintenance) for the engine type, 912 Series or 914 Series.

  • Page 220: General Information On The Fuel System

    BRP-Rotax Maintenance Manual 3.4) General information on the fuel system The most common reason for engine failure is a fault in the fuel system. Many problems can be prevented by regular checks. Contamination and formation of condensate can lead to erratic engine running or misfiring.

  • Page 221: 1) Fuel Pressure (On 912 Series)

    BRP-Rotax Maintenance Manual 3.4.1) Fuel pressure (on 912 Series) See Fig. 73-28. The pressure inside the fuel system must not exceed 0.4 bar (5.80 p.s.i). Normally, it will lie between 0.15 (2.18 p.s.i) and 0.3 bar (4.4 p.s.i). The fuel pressure tester, part no. 874230, can be used to measure the pressure and check the correct functioning of the fuel system.
  • Page 222 BRP-Rotax Maintenance Manual Fig. 73-28 00365 73-00-00 Effectivity 912 Series Edition 1 / Rev. 0 page 36 May 01/2007...

  • Page 223: 2) Fuel Pressure (On 914 Series)

    BRP-Rotax Maintenance Manual 3.4.2) Fuel pressure (on 914 Series) There is no specific connection on the engine for reading the fuel pressure. However, it makes sense to take fuel pressure readings for monitoring purposes and for troubleshooting. See latest installation manual for the respective engine type.

  • Page 224: 3) Carburetor Sockets

    BRP-Rotax Maintenance Manual 3.4.3) Carburetor sockets See Figs. 73-29, 73-30, 73-31 and 73-32. The carburetor attachment on the engine is designed to ensure that it can be securely fixed to the intake manifold with carburetor sockets (4). See 73-00-00 sec. 3.1.
  • Page 225 BRP-Rotax Maintenance Manual Fig. 73-29 00366 Fig. 73-30 05793 Fig. 73-32 Fig. 73-31 05794 05792 (0.31 in) 73-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 39 May 01/2007...

  • Page 226: 4) Fuel Lines (On 912 Series)

    BRP-Rotax Maintenance Manual 3.4.4) Fuel lines (on 912 Series) See Figs. 73-33, 73-34, 73-35, 73-36. ■ CAUTION : When removing fuel lines, support them adequately to avoid strain or additional load. Rigid fuel line The fuel line (1) is supported by a cable clamp (2) on the carburetors.
  • Page 227 (7) and sealing rings (8). The banjo bolt (9) (tightening torque 10 Nm (90 in.lb)) After that unscrew take off the fuel line. Fig. 73-34 08180 73-00-00 Effectivity 912 Series Edition 1 / Rev. 0 page 41 May 01/2007...
  • Page 228 See Fig. 73-36. ■ CAUTION : In the event of leaks, the max. permissible torque must never be exceeded. Fig. 73-35 Fig. 73-36 08212 08211 73-00-00 Effectivity 912 Series Edition 1 / Rev. 0 page 42 May 01/2007...

  • Page 229: 5) Fuel Lines (On 914 Series)

    BRP-Rotax Maintenance Manual 3.4.5) Fuel lines (on 914 Series) See Figs. 73-37 and 73-38. Each fuel line (1) is supported by a cable clamp (2) on the carburetors. The clamps are attached with allen screws M5x12 (3) and lock nuts (4).

  • Page 230: 6) Fuel Pressure Regulator (Only On 914 Series)

    BRP-Rotax Maintenance Manual 3.4.6) Fuel pressure regulator (only on 914 Series) See Figs. 73-37 and 73-38. Carry out a visual inspection of the fuel pressure regulator (2). ◆ NOTE: All new fuel pressure regulators are calibrated by the engine manufacturer and should not need further adjustment.

  • Page 231: 7) Fuel Pump (On 912 Series)

    BRP-Rotax Maintenance Manual 3.4.7) Fuel pump (on 912 Series) See Figs. 73-33, 73-39 and 73-40. Depending on the engine configuration, it may already have been fitted with a pump with fuel hoses, see Fig. 73-33. On engines without fuel hoses, observe the aircraft manufacturer’s instructions.
  • Page 232 BRP-Rotax Maintenance Manual Fig. 73-39 00367 Fig. 73-40 from tank from tank 00368 04962 to carburetor to carburetor 73-00-00 Effectivity 912 Series Edition 1 / Rev. 0 page 46 May 01/2007...

  • Page 233: 8) Fuel Pump (On 914 Series)

    BRP-Rotax Maintenance Manual 3.4.8) Fuel pump (on 914 Series) See Fig. 73-41. Two electrical fuel pumps are included in each delivery. Check of the fuel filter, see Line Maintenance 12-00-00 sec. 2.10. ◆ NOTE: The built-in screen on the suction side of the electric fuel pumps cannot be replaced.
  • Page 234 BRP-Rotax Maintenance Manual Fig. 73-41 11,75 8 ø38 ø13,3 ø12 ø8 ø9 00045 73-00-00 Effectivity 914 Series Edition 1 / Rev. 0 page 48 May 01/2007...

  • Page 235: 9) Pressure Connecting Lines (Only On 914 Series)

    BRP-Rotax Maintenance Manual 3.4.9) Pressure connecting lines (only on 914 Series) See Figs. 73-42 and 73-43. The pressure connecting lines are of essential importance for safe operation of the engine. See also 73-00-00 sec. 2 and the correspond- ing Maintenance Manual (Line Maintenance) for the respective engine type, 912 or 914 Series.
  • Page 236 BRP-Rotax Maintenance Manual ■ CAUTION: Ensure that the total slip-on length is used for all pressure connecting lines and that the clamps are fixed securely. In addition, all lines must be routed in such a way that scuffing and kinks are avoided.
  • Page 237 BRP-Rotax Maintenance Manual Fig. 73-42 00048 Fig. 73-43 130 mm (5.12 in.) 75 mm (82.95 in.) 130 mm (5.12 in.) 00049 * Length of tubes depending on installation conditions 73-00-00 Effectivity 914 Series Edition 1 / Rev. 0 page 51...
  • Page 238 BRP-Rotax Maintenance Manual NOTES 73-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 52 May 01/2007...

  • Page 239: Assembly Of Carburetor Sockets, Carburetor And Fuel Lines

    BRP-Rotax Maintenance Manual 3.5) Assembly of carburetor sockets, carburetor and fuel lines 3.5.1) Carburetors and carburetor sockets See Figs. 73-44, 73-45 and 76-46. Attach carburetor socket (1) and new O-ring (3) with two hex. screws (2) M8x25 with washers. ◆ NOTE: On intake manifolds without an O-ring groove, a gasket (4) (see Illustrated Parts Catalog) must be fitted.
  • Page 240 BRP-Rotax Maintenance Manual Fig. 73-45 (0.2 to Fig. 73-44 5÷6 mm 0.24 in.) (1.57 in.) 40 mm 05794 (0.24 in.) 02727 Fig. 73-46 07712 73-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 54 May 01/2007...

  • Page 241: 2) Fuel Lines (On 912 Series)

    BRP-Rotax Maintenance Manual 3.5.2) Fuel lines (on 912 Series) See Figs. 73-47, 73-48, 73-49 and 73-50. ■ CAUTION: To prevent locked up stresses, all components should first be screwed on loosely and then tightened to the prescribed tightening torque. If the clamp block (1) has been removed, it must now be reattached with an allen screw M5x16 and a tightening torque of 6 Nm (53 in.lb).
  • Page 242 From 2007 on, all new models will have a flexible line instead of the present rigid fuel line. Assembly at the carburetor should be carried out analogously the diassembly. See sec. 3.4.4. 73-00-00 Effectivity 912 Series Edition 1 / Rev. 0 page 56 May 01/2007...
  • Page 243 BRP-Rotax Maintenance Manual Fig. 73-48 Fig. 73-49 07513 07514 Fig. 73-50 08180 73-00-00 Effectivity 912 Series Edition 1 / Rev. 0 page 57 May 01/2007...

  • Page 244: 3) Fuel Lines (On 914 Series)

    BRP-Rotax Maintenance Manual 3.5.3) Fuel lines (on 914 Series) See Fig. 73-51. Attach fuel line (10) to carburetor (fuel inlet) with collar nut (11). Support the line on the carburetor bracket with a cable clamp (12). The cable clamps are attached with allen screws (13) M5x12 and lock nuts (14).
  • Page 245 BRP-Rotax Maintenance Manual Fig. 73-51 A Loctite 221 07713 73-00-00 Effectivity 914 Series Edition 1 / Rev. 0 page 59 May 01/2007...

  • Page 246: Intake Manifolds Fitting

    Repeat procedure for second carburetor. ◆ NOTE: Only on 912 Series: On engine models from the year 96 onwards, the carburetor support is already fitted in serial production. We recommend installing it on all engines older than this. See Service Bulletin SB-912-010,”Fitting of a carburetor support”, latest issue.

  • Page 247: Connecting Fuel Lines (Tank)

    BRP-Rotax Maintenance Manual 3.8) Connecting fuel lines (tank) The fuel lines from the tank to the fuel pump, from the fuel pump to the two carburetors and the return line to the fuel tank must be installed as per the aircraft manufacturer’s instructions when installing the engine in the aircraft.
  • Page 248 BRP-Rotax Maintenance Manual NOTES 73-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 62 May 01/2007...
  • Page 249 3.12) Measurement values for the ignition unit ........74-00-00 / 22 3.13) Wiring diagrams ................74-00-00 / 24 3.13.1) Engine internal (on the 912 Series) ........74-00-00 / 24 3.13.2 Engine internal (on the 914 Series) ........74-00-00 / 30 3.13.3 Engine external (on the 914 Series) ........
  • Page 250 3.19) Stator removal and refitting ............74-00-00 / 48 3.20) Fly wheel hub' ................74-00-00 / 49 3.21) Interference suppression box (only on the 912 Series) ....74-00-00 / 52 3.21.1) Interference suppression box dismantling ......74-00-00 / 52 3.21.2) Interference suppression box wiring diagram ...... 74-00-00 / 53 3.21.3) Interference suppression box assembly ......

  • Page 251: Systems Description

    2) Systems description 2.1.) Electric system (alternators, ignition) See Fig. 74-1. ROTAX engines of the 912/914 Series are equipped with a breakerless dual ignition system (DCDI-Dual Capacitor Discharge Ignition). The ignition unit needs no external power supply. Each of the two independent charging coils (1) located on the generator stator supplies one of the two ignition circuits.
  • Page 252 BRP-Rotax Maintenance Manual The standard equipment also includes an integrated AC generator (6) with an external rectifier-regulator (12V DC 250 W). For higher power requirements, it is possible to install an external alternator (12V DC 600W). ◆ NOTE: A rectifier-regulator is already integrated in the external alterna- tor.
  • Page 253 BRP-Rotax Maintenance Manual Fig. 74-2 07722 Fig. 74-3 07723 74-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 5 May 01/2007...

  • Page 254: 1) Ignition

    For easy engine start, the ignition timing at start is 4° B.T.D.C. for ignition circuit A and B. As soon as the engine runs, the ignition point will change over automatically to operation ignition. On the 912 Series: Ignition circuit A and B 26° On the 914 Series: ignition circuit A 26°...
  • Page 255 BRP-Rotax Maintenance Manual ◆ NOTE: The different ignition points (only on 914 Series) for the top spark plugs and the bottom spark plugs takes into account the differing ignition delays, preventing pre- ignition and detonation. The difference in the ignition points is achieved by different lengths of the trigger cam (1) on the fly wheel hub.

  • Page 256: 2) Allocation Of Trigger Coils And Ignition Circuits

    BRP-Rotax Maintenance Manual 2.1.2) Allocation of trigger coils and ignition circuits See Fig. 74-5. The upper trigger coils A1/2 and A3/4 (raised approx. 5 mm (0.20 in.)) control the top electronic module. i.e. Ignition circuit A: top trigger coil - top electronic module...

  • Page 257: 3) Firing Order

    BRP-Rotax Maintenance Manual 2.1.3) Firing order The firing order is 1 - 4 - 2 - 3. 2.1.4) Ignition cables The 8 ignition cables of the spark plug connectors are marked with number 1 through 4 for cylinder assignment. 2 cables each for the bottom spark plugs are routed together in a protection hose between the cylinder heads.
  • Page 258 BRP-Rotax Maintenance Manual NOTES 74-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 10 May 01/2007...

  • Page 259: Maintenance / Troubleshooting

    The following sections describe maintenance procedure for engines of the 912/914 Series above and beyond the maintenance and special checks, see corresponding Maintenance Manual (Line Maintenance) for the respective engine type, 912 Series or 914 Series, and the systems descriptions given hitherto. The description is subdivided into subsections and descriptions of the function of the various systems.

  • Page 260: Spark Plugs

    BRP-Rotax Maintenance Manual 3.3) Spark plugs See Figs. 74-6 and 74-7. Inspection of the resistance spark plugs: check electrode gap, dimension (SP01), see 74-00-00 sec. 4. check heat range, see 71-00-00 sec. 3.4. See the latest Maintenance Manual "Line Maintenance“ for the respective engine type.
  • Page 261 BRP-Rotax Maintenance Manual Check all cables and their plug connections for damage and correct connection as per wiring diagram. See 74-00-00 sec. 3.13. Check all plug- and screwed connections for oxidation and tight fit. Check shorting cables and ignition switch. If ignition switch failure is suspected, the shorting cable can be pulled off the ignition switch.

  • Page 262: Electronic Module, Trigger Coil Kit

    ■ CAUTION: On the 914 Series, the ignition points for circuit A and B differs from that on ROTAX engine 912 ! In the event of failure of an ignition circuit on the 914 Series, the two 6-pin plug connectors...

  • Page 263: Charging Coil

    BRP-Rotax Maintenance Manual 3.6) Charging coil See Fig. 74-12. In case of malfunction of one ignition circuit, the 2 single-pin plugs of the red charging cables may be interchanged for localization of the problem. If the failure remains on the same ignition circuit, the electronic module is the cause and the respective module must be replaced see 74-00-00 sec.

  • Page 264: Generator Coils

    BRP-Rotax Maintenance Manual 3.7) Generator coils See Fig. 74-12. If the generator does not work, the reason may be a defective or damaged yellow alternator cable or a defective winding on the 8 alternator coils (3). Disconnect alternator cables (yellow) and check resistance values.

  • Page 265: Dual Ignition Coil

    BRP-Rotax Maintenance Manual 3.8) Dual ignition coil See Figs. 74-13 and 74-14. If the failure of a single resistance spark plug or 2 resistance spark plugs is noticed, check the connections and the resistance values of the respective dual ignition coil, see 74-00-00 sec. 3.12 The iron core (1) must not be loose.

  • Page 266: Cut-In Speed Of Ignition

    BRP-Rotax Maintenance Manual 3.9) Cut-in speed of ignition See Fig. 74-15 Ignition must cut-in between 150 rpm. and max. 220 rpm. of crankshaft speed. To be checked with stroboscope and inductive pliers (see 00-00-00 sec. 10.5). For this procedure, connect stroboscope (1) to battery (2) and clamp inductive pliers (3) to the ignition cable of cylinder 1 (top) or cylinder 2 (top).

  • Page 267: Ignition Timing Control

    At an engine speed of 150 to max. 1000 rpm,. the trailing edge of the trigger cam (3) aligns with the core (4) of the trigger coil. Trigger coil assignation (on the 912 Series) Trigger coil A1/2 serves the top spark plug of cylinder 1 and 2 Trigger coil A3/4 serves the bottom spark plug of cylinder 3 and 4.
  • Page 268 BRP-Rotax Maintenance Manual Start ignition timing B3/4 A1/2 Fig. 74-16 A3/4 07486 B1/2 Operating ignition timing B3/4 Fig. 74-17 A1/2 A3/4 07487 B1/2 74-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 20 May 01/2007...

  • Page 269: Ignition Circuits Inspection (Ignition Check)

    BRP-Rotax Maintenance Manual 3.11) Ignition circuits inspection (ignition check) Let engine warm up. The ignition check is performed at an engine speed of approx. 4000 rpm (approx. 1700 propeller speed). Switch off ignition circuit "A" with ignition switch. This causes only 1 spark plug per cylinder to fire.

  • Page 270: Measurement Values For The Ignition Unit

    BRP-Rotax Maintenance Manual 3.12) Measurement values for the ignition unit The following measurement values can be checked at the appropriate point after detaching the plug connections. Generator coil 0.8 Ω (on stator) yellow yellow 0.1 to ∞ Generator coil yellow...
  • Page 271 BRP-Rotax Maintenance Manual NOTES 74-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 23 May 01/2007...

  • Page 272: Wiring Diagrams

    BRP-Rotax Maintenance Manual 3.13) Wiring diagrams 3.13.1) Engine internal (on the 912 Series) Wiring diagram of the ignition unit ("individual plug"), 912 Series See Figs. 74-18, 74-19 and 74-20. Legend to wiring diagram (Fig. 74-18) ignition magneto generator trigger coil for ignition circuit ”A”...
  • Page 273 3 - 4 TOP 0,75 br blue 0,75 sw brown 0,75 br 0,75 sw ge yellow gn green 0,5 ws/ge 0,5 bl/ge pink sw black ws white orange 00403 74-00-00 Effectivity 912 Series Edition 1 / Rev. 0 page 25 May 01/2007...
  • Page 274 ”A” electronic module for ignition circuit ”B” double ignition coil engine cylinder 1 - 4 spark plugs charging coils consumer connection color code 74-00-00 Effectivity 912 Series Edition 1 / Rev. 0 page 26 May 01/2007...
  • Page 275 3 - 4 TOP blue 0,75 sw brown 0,75 br 0,75 sw ge yellow gn green 0,5 ws/ge 0,5 bl/ge pink sw black ws white orange 04702 74-00-00 Effectivity 912 Series Edition 1 / Rev. 0 page 27 May 01/2007...
  • Page 276 ”A” electronic module for ignition circuit ”B” double ignition coil engine cylinder 1 - 4 spark plugs charging coils consumer connection color code 74-00-00 Effectivity 912 Series Edition 1 / Rev. 0 page 28 May 01/2007...
  • Page 277 3 - 4 TOP 0,75 br blue 0,75 sw brown ge yellow 0,75 br 0,75 sw gn green 0,5 ws/ge 0,5 bl/ge pink sw black ws white orange 05808 74-00-00 Effectivity 912 Series Edition 1 / Rev. 0 page 29 May 01/2007...

  • Page 278: Engine Internal (On The 914 Series)

    BRP-Rotax Maintenance Manual 3.13.2 Engine internal (on the 914 Series) See Figs. 74-21 and 74-22. Legend to wiring diagram (Fig. 74-21) ignition magneto generator trigger coil for ignition circuit ”A” trigger coil for ignition circuit ”B” trigger coil for rev counter...
  • Page 279 BRP-Rotax Maintenance Manual T = top = oben Fig. 74-21 B = bottom = unten B ge B ws B 1/2 B 3/4 A ws A ge A 1/2 A 3/4 Magnetseite Engine version 914 UL/F (magneto side) A 3/4...
  • Page 280 BRP-Rotax Maintenance Manual Legend to wiring diagram (Fig. 74-22) ignition magneto generator trigger coil for ignition circuit ”A” trigger coil for ignition circuit ”B” trigger coil for rev counter plug receptacle 2-pin electronic rev counter grounding switch for ignition circuit ”A” and ”B”...
  • Page 281 BRP-Rotax Maintenance Manual T = top = oben Fig. 74-22 B = bottom = unten B ge B ws B 1/2 B 3/4 A ge A ws A 1/2 A 3/4 Engine version 914 UL/F Magnet- new model seite ◆ NOTE: Fig.

  • Page 282: Engine External (On The 914 Series)

    BRP-Rotax Maintenance Manual 3.13.3 Engine external (on the 914 Series) See latest Installation Manual for engines of the 914 Series and 76-00-00 sec. 3.1.2.3. 74-00-00 Effectivity 914 Series Edition 1 / Rev. 0 page 34 May 01/2007...

  • Page 283: Ignition Electric Set Removal

    BRP-Rotax Maintenance Manual 3.14) Ignition electric set removal See Fig. 74-23 The ignition electric set, consisting of 2 electronic modules and 4 dual ignition coils, is fitted to the engine on 3 rubber buffers. For removal, detach all 8 spark plug connectors (1) from the spark plugs.
  • Page 284 BRP-Rotax Maintenance Manual Fig. 74-23 00334 74-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 36 May 01/2007...

  • Page 285: Ignition Electric Set Dismantling

    BRP-Rotax Maintenance Manual 3.15) Ignition electric set dismantling See Figs. 74-24 and 74-25. ◆ NOTE: Before removal, mark all 8 ignition cables resp. check the correct application of the identification rings (1)-(2)-(3 )-(4) of cylinders no. 1 through 4 to avoid mix-up at reassembly.
  • Page 286 BRP-Rotax Maintenance Manual On newer engine versions (electronic module with 6+ 4 pin plug): See Fig. 74-25. When replacing a dual ignition coil, the following dismantling procedure is required: Remove hex. nut M6 (11) and rubber buffer (12) with bracket (13).
  • Page 287 BRP-Rotax Maintenance Manual For older engine models Fig. 74-24 8 26 23 17 00406 74-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 39 May 01/2007...
  • Page 288 BRP-Rotax Maintenance Manual For new engine models Fig. 74-25 A LOCTITE 221 I: LITHIUMSEIFENFETT LITHIUM BASE GREASE S SILIKON WÄRMELEITPASTE SILICONE HEAT COMPOUND 07727 74-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 40 May 01/2007...

  • Page 289: Ignition Electric Set Reassembly

    BRP-Rotax Maintenance Manual 3.16) Ignition electric set reassembly On older engine versions (electronic module with 1+ 4 pin plug): See Figs. 74-18, 74-19, 74-21 and 74-24. Re-assembly of dual ignition coils in reverse order. Attach the dual ignition coils offset and in the correct position as per drawing, with the two allen screws M6x30 (20) and lock washers A6 with distance nut M6 (21).
  • Page 290 BRP-Rotax Maintenance Manual Attach the dual ignition coils offset and in the correct position with fixation latch (37) and connector holder (42) as per drawing, with the two allen screws M6x30 (20) and lock washers A6 with distance nut M6 (21). Pay attention to the dual ignition coil (23) for spark plugs 3B and 4B.

  • Page 291: Ignition Electric Set Refitting

    BRP-Rotax Maintenance Manual 3.17) Ignition electric set refitting On older engine versions (electronic module with 1+ 4 pin plug): See Figs. 74-24 and 74-26. Insert O-rings (33) 34x2 in the groove (34) of the cylinder heads and remove the plugs from the intake openings. Fit both intake manifolds (35) with pre- assembled ignition electric set and tighten crosswise with 4 allen screws M6x25/ 70 and lock washers.
  • Page 292 BRP-Rotax Maintenance Manual On newer engine versions (electronic module with 6+ 4 pin plug): See Figs. 74-25 and 74-27. Remove plugs from the intake openings and insert O-rings (33) 34x2 in the groove (34) of the cylinder heads. Fit both intake manifolds (35) with pre- assembled ignition electric set and tighten crosswise with 4 allen screws M6x25/ 70 and lock washers.
  • Page 293 BRP-Rotax Maintenance Manual Fig. 74-26 Fig. 74-27 00408 05820 74-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 45 May 01/2007...

  • Page 294: Trigger Coil Kit Replacement

    BRP-Rotax Maintenance Manual 3.18) Trigger coil kit replacement See Figs. 74-28, 74-29, 74-30, 74-31, 74-32 and 74-33. Because of the shielding (6), the trigger coil kit (5) can be exchanged only as a complete set. Remove the attachment screws (7) with the distance sleeves (8) and cable clamps and fit new trigger coil kit.
  • Page 295 BRP-Rotax Maintenance Manual Fig. 74-28 Fig. 74-29 IH03 On older engine models IH02 On new engine models („clip on pickup“) 07728 00089 Fig. 74-31 Fig. 74-30 07138 07139 74-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 47 May 01/2007...

  • Page 296: Stator Removal And Refitting

    BRP-Rotax Maintenance Manual 3.19) Stator removal and refitting See Figs. 74-32, 74-33 and 74-34. Lock crankshaft with the thread bolt, part no. 240880 See also 75-00-00. Remove hex. screw (10) M16x1.5 together with lock washer and washers. Place protection piece, part no. 877410, on crankshaft, screw puller, part no. 877375, fully onto the thread (11) and press off fly wheel hub (12) together with magneto ring with the hex.

  • Page 297: Fly Wheel Hub

    BRP-Rotax Maintenance Manual 3.20) Fly wheel hub' See Fig. 74-32. Carry out visual inspection of magneto inner side (16) and the taper surface (17). Under normal circumstances, dismantling of fly wheel hub is not necessary. If it has been dismantled, clean the contact faces (18) Apply LOCTITE 221 to all 10 allen screws (19) (alternating 5 screws M6x30 and 5 screws M6x25) and screw together.
  • Page 298 BRP-Rotax Maintenance Manual Older engine models Fig. 74-32 07729 74-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 50 May 01/2007...
  • Page 299 BRP-Rotax Maintenance Manual New engine models Fig. 74-33 Fig. 74-34 07730 07731 74-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 51 May 01/2007...

  • Page 300: Interference Suppression Box (Only On The 912 Series)

    BRP-Rotax Maintenance Manual 3.21) Interference suppression box (only on the 912 Series) See Fig. 74-35. ◆ NOTE: Fitted in serial production up to 1995! 3.21.1) Interference suppression box dismantling The interference suppression box contains two electronic boxes, four dual ignition coils and two capacitors. Each interference suppression box bears a consecutive serial number on the cover.

  • Page 301: 2) Interference Suppression Box Wiring Diagram

    BRP-Rotax Maintenance Manual 3.21.2) Interference suppression box wiring diagram weiß weiß Kondensator A1/2 A3/4 B3/4 B1/2 04787 Zündab- schaltung: Fig. 74-35 Kondensator oben: Zündkreis A Kondensator unten: Zündkreis B IGNITION CIRCUIT A IGNITION CIRCUIT B (1) alternator cable, red (6) alternator cable, red (from stator)

  • Page 302: 3) Interference Suppression Box Assembly

    BRP-Rotax Maintenance Manual 3.21.3) Interference suppression box assembly The interference suppression box is assembled in reverse order. Always observe the wiring diagram for the interference suppression box. Lithiumbase grease must be applied to all cable connections to prevent leakage current.

  • Page 303: Rev Counter And Ignition Trigger Coils

    BRP-Rotax Maintenance Manual 3.22) Rev counter and ignition trigger coils See Figs. 74-36 and 74-37. ◆ NOTE: All 5 trigger coils are of equal design. Therefore this checking procedure is valid for the ignition trigger coils too. The rev counter trigger coil (3) is fitted on the ignition housing.
  • Page 304 BRP-Rotax Maintenance Manual Fig. 74-37 Fig. 74-37 shows oscilloscope images of the rev counter signal at different loads and speeds. Speed 500 rpm (load 100 Ω Ω Ω Ω Ω ) Speed 6000 rpm (load 100 kΩ Ω Ω Ω Ω )

  • Page 305: External Alternator (Optional On 912/914 Series)

    BRP-Rotax Maintenance Manual 3.23) External alternator (optional on 912/914 Series) 3.23.1) Vbelt pulley assembly See Fig. 74-38. Slide the pulley (1) fully over the propeller flange (2) and insert the V- belt 9.5x675 (3) loosely in the Vbelt pulley. Insert the two pulley carriers (4) with the centering (5) facing the inside (6) of the propeller flange and loosely preassemble the propeller with the two pulley carriers.
  • Page 306 BRP-Rotax Maintenance Manual Fig. 74-38 07526 20 23 22 74-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 58 May 01/2007...

  • Page 307: 3) V-Belt Tension

    BRP-Rotax Maintenance Manual 3.23.3) V-belt tension See latest Maintenance Manual "Line Maintenance“ for the respective engine type. 74-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 59 May 01/2007...
  • Page 308 BRP-Rotax Maintenance Manual NOTES 74-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 60 May 01/2007...

  • Page 309: Wear Limits

    BRP-Rotax Maintenance Manual 4) Wear limits SP01 IH03 00086 07510 F = 50N AL01 07515 74-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 61 May 01/2007...
  • Page 310 BRP-Rotax Maintenance Manual 07201 wear wear Reading new limit limit Description Readings 100% Spark plug actual Elektrodenabstand SP01 0,022 0,028 0,036 renewed Ignition housing A 1/2 A 3/4 B 1/2 B 3/4 actual trigger coil gap "old IH02 type" 0,016...

  • Page 311: Form Sheets

    BRP-Rotax Maintenance Manual 5) Form Sheets 06754 Fig. 74-39 74-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 63 May 01/2007...
  • Page 312 BRP-Rotax Maintenance Manual NOTES 74-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 64 May 01/2007...
  • Page 313 BRP-Rotax Maintenance Manual SECTION 75 COOLING SYSTEM 1) Table of contents SECTION 75 COOLING SYSTEM 1) Table of contents ..................75-00-00 / 1 2) Systems description ................. 75-00-00 / 3 2.1) Cooling system ................75-00-00 / 3 2.2) Connections for instrumentation ........... 75-00-00 / 4 2.2.1) Cylinder head temperature display ........
  • Page 314 BRP-Rotax Maintenance Manual NOTES 75-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 2 May 01/2007...

  • Page 315: Systems Description

    Cooling system See Fig. 75-1. The cooling system of the ROTAX 912/914 Series is designed for liquid cooling of the cylinder heads and ram-air cooling of the cylinders. The cooling system of the cylinder heads is a closed circuit with an expansion tank.

  • Page 316: Connections For Instrumentation

    BRP-Rotax Maintenance Manual Fig. 75-1 00125 2.2) Connections for instrumentation ■ CAUTION: Consult also the relevant sections on connections for instru- mentation in the latest Installation Manual. 2.2.1) Cylinder head temperature display There are temperature sensors screwed in to the cylinder heads of cylinders 2 and 3.

  • Page 317: Maintenance

    The following sections describe maintenance procedure for engines of the 912/914 Series above and beyond the maintenance and special checks, see corresponding Maintenance Manual (Line Maintenance) for the respective engine type, 912 Series or 914 Series, and the systems descriptions given hitherto. The description is subdivided into subsections and descriptions of the function of the various systems.

  • Page 318: Water Pump Removal And Inspection

    To remove the hex. screw (3) M16x1.,5 from the fly wheel hub, the crankshaft must be locked. See the corresponding Maintenance Manual (Line Mainte- nance) for the respective engine type, 912 Series or 914 Series. Fig. 75-2 00344...

  • Page 319: Water Pump Housing - Dismantling And Inspection

    5 turns. Normally, fittings with a bend angle of 45° are fitted. On the 914 engine and engines with ROTAX engine suspension frame, there is a fitting with a bend angle of 80° fitted at cylinder 2.
  • Page 320 BRP-Rotax Maintenance Manual Fig. 75-3 Cyl. 3 Cyl. 1 Cyl. 4 Cyl. 2 00377 75-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 8 May 01/2007...

  • Page 321: Fly Wheel Hub Removal

    BRP-Rotax Maintenance Manual 3.3) Fly wheel hub removal See 72-00-00 sec. 3.1. 3.4) Ignition housing removal See 72-00-00 sec. 3.3. 3.5) Water pump shaft - removal See Figs. 75-4 and 75-5. It is an advantage to loosen the impeller when dismantling the engine (with crankshaft locked).

  • Page 322: Rotary Seal - Removal

    BRP-Rotax Maintenance Manual 3.6) Rotary seal - removal See Fig. 75-6. Remove old shaft seal and rotary seal using 2 pins (1) of 5 mm (0.2 in.) diameter and a suitable punch (2). Shaft seal and rotary seal will be destroyed during removal and must be replaced.
  • Page 323 BRP-Rotax Maintenance Manual Fig. 75-6 Fig. 75-7 00386 00387 Fig. 75-9 Fig. 75-8 00389 00388 75-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 11 May 01/2007...

  • Page 324: Axial Position Of The Water Pump Shaft

    BRP-Rotax Maintenance Manual 3.8) Axial position of the water pump shaft See Fig. 75-10 Check axial position of water pump shaft and pump gear. The step (6) of the gear points inward towards the crankcase. ◆ NOTE: To ensure the correct gap (8) (dimension WP02) between the...

  • Page 325: Ignition Housing Assembly

    BRP-Rotax Maintenance Manual 3.9) Ignition housing assembly See 72-00-00 sec. 3.5. 3.10) Water pump housing — reassembly See Fig. 75-11. Position gasket (1), attach water pump housing (2) to the ignition housing with 2 allen screws (3) M6x90 and 3 allen screws (4) M6x35 together with lock washers, torque to 10 Nm (90 in.lb).

  • Page 326: Coolant Hoses Fitting

    BRP-Rotax Maintenance Manual 3.11) Coolant hoses fitting See Fig. 75-12 ■ CAUTION: The spring band hose clamps must be installed in the drawn origin position. (See sketch) 08341 Fit all coolant hoses (1) coming from the expansion tank to the coolant exit on the cylinder heads (3) with spring band hose clamps (4).

  • Page 327: Expansion Tank

    SB-912-039 and SB-914-025, “Modifications of the overflow bottle“, latest issue. 3.17) Temperature measurement system ◆ NOTE: There are several temperature control points on ROTAX en- gines of the 912/914 Series. Refer to wiring diagram in Operators Manual. 3.17.1) Cylinder head temperature sensor See Figs.
  • Page 328 BRP-Rotax Maintenance Manual Fig. 75-12 04555 75-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 16 May 01/2007...
  • Page 329 BRP-Rotax Maintenance Manual Fig. 75-13 00327 (Ω) Fig. 75-14 1200 1000 140 160 (°C) 00327 75-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 17 May 01/2007...
  • Page 330 BRP-Rotax Maintenance Manual NOTES 75-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 18 May 01/2007...

  • Page 331: Wear Limits

    BRP-Rotax Maintenance Manual 4) Wear limits WP01 07509 WP02 07511 wear wear 07202 Reading new limit limit Description Readings 100% Water pump actual 8,55 8,85 8,85 reference dim. WP01 0,3366 0,3484 0,3484 renewed actual impeller clearance WP02 0,012 0,020 0,028...
  • Page 332 BRP-Rotax Maintenance Manual NOTES 75-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 20 May 01/2007...
  • Page 333 BRP-Rotax Maintenance Manual SECTION 76 ENGINE CONTROL 1) Table of contents SECTION 76 ENGINE CONTROL 1) Table of contents ..................76-00-00 / 1 2) Systems description ................. 76-00-00 / 3 2.1) Turbocharger control (only on 914 Series) ........76-00-00 / 3 2.1.1) Control of boost pressure in the airbox ......
  • Page 334 BRP-Rotax Maintenance Manual 3.1.2) Static check of the turbocharger control ......76-00-00 / 32 3.1.2.1) Turbo control unit (TCU) ..........76-00-00 / 32 3.1.2.2) Caution lamps ............. 76-00-00 / 34 3.1.2.3) Wiring harness ............76-00-00 / 35 3.1.2.4) Throttle potentiometer ..........76-00-00 / 37 3.1.2.5) Resistance thermometer (Intake air...

  • Page 335: Systems Description

    BRP-Rotax Maintenance Manual 2) Systems description 2.1) Turbocharger control (only on 914 Series) 2.1.1) Control of boost pressure in the airbox See Figs. 76-1, 76-2, 76-3, 76, -4 and 76-5. The position of the carburetor throttle valves is signalled by a potenti- ometer to the TCU, where it is transformed in a chosen pattern into target pressure in the airbox.
  • Page 336 BRP-Rotax Maintenance Manual The electronic regulator (4) TCU (Turbo Control Unit) is the “central processing unit” as the junction of all engine parameter inputs. For functioning of the TCU, the following sensors e.g. trigger coils are required. Airbox pressure sensor (5)
  • Page 337 BRP-Rotax Maintenance Manual The following diagram shows the pressure regulating sequence for the newer TCU versions (TCU No. 966741 or higher) (Fig. 76-2). 00170 Fig. 76-2 46 in. HG 1500 1400 1300 1200 1100 1000 110 115 % The airbox target pressures for engine operation with newer TCU...
  • Page 338 BRP-Rotax Maintenance Manual ■ CAUTION: Prolonged engine operation is not allowed between max. continuous performance (100 %) and take-off performance (115 %). The target pressure rises rapidly between these throttle positions (108 to 110 %) and attempts should not be made to remain in this phase but instead to move speedily through this range in both directions to prevent control fluctuations.
  • Page 339 BRP-Rotax Maintenance Manual Fig. 76-5 00139 (1) Turbocharger (9) Resistance thermometer, Airbox temp. (2) wastegate (10) Wiring harness (3) Servo motor (11) Voltage supply (4) TCU (12) Lamps (5) Ambient pressure sensor (13) Three-way solenoid valve (6) Airbox pressure sensor...

  • Page 340: 2) Target Pressure Reduction

    BRP-Rotax Maintenance Manual 2.1.2) Target pressure reduction Provision for target pressure reduction is made depending on various effects as a protective measure against overstressing the engine. 2.1.2.1) Target pressure reduction at overspeeding See Fig. 76-6 It is the responsibility of the pilot to prevent engine speeds in...

  • Page 341: 2) Target Pressure Reduction At Excessive Airbox

    BRP-Rotax Maintenance Manual 2.1.2.2) Target pressure reduction at excessive airbox tempera- ture See Figs. 76-7 and 76-8. During the compression process in the turbocharger, the intake air is heated. To reduce the risk of detonation at high boost pressure with high intake air temperature, lowering of the target pressure starts at 88 °C (190 °F) airbox tempera-...

  • Page 342: 3) Target Pressure Reduction By Limiting The Compressor

    BRP-Rotax Maintenance Manual 2.1.2.3) Target pressure reduction by limiting the compressor pressure ratio To prevent vibration resonance, the max. turbo charger speed of approx. 165 000 rpm must not be exceeded . Since the turbo charger speed can be deduced exactly enough from the pressure ratio, this ratio is limited to max.

  • Page 343: 3) Lamp Output Connections On The Tcu

    BRP-Rotax Maintenance Manual 2.1.3) Lamp output connections on the TCU The TCU is furnished with output connections for an external „red“ boost lamp and an „orange“ caution lamp. When the TCU is switched on, the two lamps are automatically subjected to a function test. Both lamps light up for 1 to 2 seconds and then go out.

  • Page 344: 4) Three-Way Solenoid Valve

    BRP-Rotax Maintenance Manual 2.1.4) Three-way solenoid valve 3 The TCU also controls the 3way solenoid valve, which causes various pressures to become active on the float chamber of the carburetors. For further information, see 73-00-00 sec. 2.8. ◆ NOTE: The solenoid valve is inactive below the threshold.

  • Page 345: Maintenance

    The following sections describe maintenance procedure for engines of the 912/914 Series above and beyond the maintenance and special checks, see corresponding Maintenance Manual (Line Maintenance) for the respective engine type, 912 Series or 914 Series, and the systems descriptions given hitherto. The description is subdivided into subsections and descriptions of the function of the various systems.
  • Page 346 BRP-Rotax Maintenance Manual - Communication program: Software between TCU and computer tlr V4.3a for TCU part no. 966470 and 966471 tlr V4.5a for TCU part no. 966472 and 966473 tlr V4.6a for TCU part no. 966741 - Decoding unit (Dongle) with data cable to connect with computer ◆...

  • Page 347: 3) Scope Of The Communication Program

    Maintenance Manual 3.1.1.3) Scope of the communication program a) Software The software is the property of BRP-Rotax. Duplication is only permissible for the purpose of copying onto the hard disk or for the creation of backup copies or for filing.
  • Page 348 BRP-Rotax Maintenance Manual Dekodereinheit Fig. 76-11 (Dongle) zum PC (to PC) zur TCU (to TCU) zur Dekodiereinheit (to Dongle) Laptop Kommunikationsprogramm (communicationprogram) 00209 76-00-00 Effectivity 914 Series Edition 1 / Rev. 0 page 16 May 01/2007...

  • Page 349: 4) Application Of The Communication Program

    BRP-Rotax Maintenance Manual c) Procedure for installation of the communication pro- gram on the PC - Check which TCU part no. and thus which program version is applicable. TCU part no. Program version 966470 TLR43A.exe 966471 TLR45A.exe 966472 TLR45A.exe 966473 TLR45A.exe...
  • Page 350 BRP-Rotax Maintenance Manual b) Starting the subprograms: See Fig. 76-12 The subprograms are listed in the bottom line and are started by keying in first letter of the program name, e.g. “M” for MONITOR (monitor program) ◆ NOTE: The key “ESC” will always return you to the main menu.
  • Page 351 BRP-Rotax Maintenance Manual NOTES 76-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 19 May 01/2007...
  • Page 352 BRP-Rotax Maintenance Manual Fig. 76-14 TCU part no. 966741 03066 TCU part no. 966470 up to 966473 00444 76-00-00 Effectivity 914 Series Edition 1 / Rev. 0 page 20 May 01/2007...
  • Page 353 BRP-Rotax Maintenance Manual Legend to monitor display Rev counter display Throttle valve position Pressure difference between (8) and (9) LOG status ON/OFF Target pressure on basis of throttle valve position Target pressure on basis of pressure ratio between (9) and (10) effective target pressure input (possibly reduced, e.g.
  • Page 354 BRP-Rotax Maintenance Manual ◆ NOTE: Because of the multitude of displays, param- eters important for the user are printed in bold type and underlined. MONITOR: Serves for the on-line display of operational engine data such as airbox pressure, ambient pressure, servo position, airbox temperature etc.
  • Page 355 BRP-Rotax Maintenance Manual Subsequent to recording, the data can be stored on a diskette or printed for evaluation. The created LOG-files are text files which can be used for further data editing in text and table calculation programs. Fig. 76-16, for instance, shows usage of data on an EXCEL spreadsheet.
  • Page 356 BRP-Rotax Maintenance Manual pressure nominal actual ambient time PC speed load throttle (0- servo position (0 output servo difference pressure pressure pressure knocking airbox (°C) P-factor I-factor D-factor (hh:mm:ss) (1/min) 115%) - 100 zu) (+/-100) (mbar) (mbar) (mbar) (mbar) 16:53:01...
  • Page 357 BRP-Rotax Maintenance Manual 00194 Fig. 76-17 2_SCOPE: For on-line display of the control action be- tween target pressure and effective airbox pressure in the range of 1000 to 1400 hPa (mbar). The program is for graphic evaluation of the parameters (8) and (9) in the monitor pro- gram.
  • Page 358 BRP-Rotax Maintenance Manual - Data display See Figs. 76-19, 76-20, 76-21, 76, -22 and 76-23. HISTORY_BUFFER: A subprogram for reading, displaying and printing of the data stored in the TCU. Fig. 76-21 shows that 8 control parameters are displayed. The recording takes place at 6 minute intervals, whereby the highest value of each period will be stored.
  • Page 359 BRP-Rotax Maintenance Manual VIEW_DATA: Shows the file data deduced from READ_DATA on the screen. The keys “page up” and “page down” enable paging on the screen. 00201 Fig. 76-21 PRINT_DATA: Option to print data deduced from READ_DATA. 00205 Fig. 76-22...
  • Page 360 A corresponding trouble shooting chart is avail- able on request from authorized distributors and service centers. See latest Operators Manual for the respective engine type or the official Homepage www.rotax-aircraft- engines.com. 76-00-00 Effectivity 914 Series Edition 1 / Rev. 0...

  • Page 361: 6) Checking The Throttle Valve Position

    BRP-Rotax Maintenance Manual 3.1.1.6) Checking the throttle valve position See Figs. 76-24 and 76-25. - Start-up of the subprogram MONITOR. At the top in the center (1) is the position display for the throttle valve (carburetor 2/4) Fig. 76-25 00445 Program version TLR V4.3A...
  • Page 362 Recalibration to be carried out only by an authorized ROTAX- Dealer or Service Center if the TCU is of part no. 966470 to 966473 .

  • Page 363: 7) Recalibration Of The Throttle Position

    BRP-Rotax Maintenance Manual 3.1.1.7) Recalibration of the throttle position See Figs. 76-26, 76-27 and 76-28. - Start up of the sub program THROTTLE. - Check whether the throttle valve (carburetor 2/4) can be fully opened and closed. Verify that the Bowden cables allow the complete travel from stop to stop.

  • Page 364: 2) Static Check Of The Turbocharger Control

    BRP-Rotax Maintenance Manual 3.1.2) Static check of the turbocharger control The easiest way to check function of turbocharger control components is by the communication program. If this program is not at your disposal, the following static checks can be carried out.
  • Page 365 - Test run engine. See the corresponding Maintenance Manual (Line Maintenance) for the respective engine type, 912 Series or 914 Series. - When switching on the TCU, observe self test of the servo motor, see 76-00-00 sec. 3.1.2.7 and the caution lamps, see 76-00-00 sec.

  • Page 366: 2) Caution Lamps

    BRP-Rotax Maintenance Manual 3.1.2.2) Caution lamps See Fig. 76-30 The TCU is furnished with output terminals for an external red boost lamp (WARNING LAMP) and an orange caution lamp. Location of the lamps depends on type of aircraft and is limited by the length of the wiring harness.

  • Page 367: 3) Wiring Harness

    BRP-Rotax Maintenance Manual 3.1.2.3) Wiring harness See Fig. 76-31 The sensors are connected with the TCU via the wiring harness. ▲ WARNING: If an inspection reveals irregularities, then the engine must not be taken in operation until the cause is found and rectified.
  • Page 368 BRP-Rotax Maintenance Manual Fig. 76-31 00211 76-00-00 Effectivity 914 Series Edition 1 / Rev. 0 page 36 May 01/2007...

  • Page 369: 4) Throttle Potentiometer

    If this aid is not at your disposal, an engine test run has to be performed. See the corresponding Maintenance Manual (Line Maintenance) for the respective engine type, 912 Series or 914 Series. Engine operation is only permissible for transfer to the nearest maintenance facility, where this check has to be performed afterwards.
  • Page 370 BRP-Rotax Maintenance Manual When reassembling the original throttle potentiometer, it is not necessary to dismantle the adapter flange (2). This would increase the installation tolerance unnecessarily. When replacing the throttle potentiometer, pay attention to the version used and if necessary, also remove the adapter flange.
  • Page 371 BRP-Rotax Maintenance Manual adapter flange older model version part no. 861930 newer model version part no. 861931 cut off edge Fig. 76-36 05378 potentiometer older model version part no. 866480 newer model version part no. 866481 Fig. 76-37 05379 distinguishing feature ◆...
  • Page 372 BRP-Rotax Maintenance Manual Resistance between the connections (6) and (7): Throttle valve closed (throttle lever pos. 0%): 3.4 to 4.6 kΩ Throttle valve open (throttle lever pos. 115%): 0.8 to 2.0 kΩ ◆ NOTE: Check complete operating range as shown in the following diagram (Fig.
  • Page 373 BRP-Rotax Maintenance Manual Resistance between the connections (5) and (6): Throttle valve open (throttle lever pos. 115%): 2.4 to 3.2 kΩ Throttle valve closed 100 to 300 Ω (throttle lever pos. 0%): ◆ NOTE: Check complete operating range as shown in the following diagram (Fig.

  • Page 374: 5) Resistance Thermometer

    BRP-Rotax Maintenance Manual 3.1.2.5) Resistance thermometer (Intake air temperature sen- sor) See Figs. 76-40, 76-41 and 76-42. The sensors (1) for measuring intake air temperature is screwed into the airbox. ■ CAUTION: In the event of physical damage or resistance readings outside allowance, replace part with- out delay.
  • Page 375 BRP-Rotax Maintenance Manual Fig. 76-40 Fig. 76-41 00056 00055 Fig. 76-42 00223 Temperatur [°C] temperature 76-00-00 Effectivity 914 Series Edition 1 / Rev. 0 page 43 May 01/2007...

  • Page 376: 6) Pressure Sensors

    BRP-Rotax Maintenance Manual 3.1.2.6) Pressure sensors See Fig. 76-43. To prevent mixup of the two pressure sensor inputs, the plug connections are in different colors. In addition, the airbox pressure sensor cable set of the wiring harness is labeled. Gray plug connection (1) - ambient pressure sensor...
  • Page 377 BRP-Rotax Maintenance Manual static pressure sensors Fig. 76-43 00057 76-00-00 Effectivity 914 Series Edition 1 / Rev. 0 page 45 May 01/2007...
  • Page 378 BRP-Rotax Maintenance Manual a) Airbox pressure sensor: See Figs. 76-44 and 76-45. On engines with an airbox of older configuration, the installa- tion location of the airbox pressure sensor (2) depends on the aircraft type and is limited by the length of the wiring harness.
  • Page 379 BRP-Rotax Maintenance Manual Test set-up Connect pin (4) to ground and connect pin (5) to positive side of voltage supply Us. Apply test pressure to sensor (input 6) Take reading of output voltage between pin (4) and pin (3). Divide the measured output voltage (Ua) by the supply voltage (Us).
  • Page 380 BRP-Rotax Maintenance Manual b) Static pressure sensor: See Figs. 76-46 and 76-47. The location of the ambient pressure sensor (1) depends on the aircraft type, but is limited by the length of the wiring harness. ■ CAUTION: The sensor is designed for a pressure range of 100 hPa to 1200 hPa and the max.
  • Page 381 BRP-Rotax Maintenance Manual Test set-up Connect pin (4) to ground and connect pin (5) to positive side of voltage supply Us. Apply test pressure to sensor (input 6) Take reading of output voltage between pin (4) and pin (3). Divide the measured out put voltage (Ua) by the supply voltage (Us).

  • Page 382: 7) Servo Motor

    BRP-Rotax Maintenance Manual 3.1.2.7) Servo motor See Fig. 76-48 The installation location of the servo motor (1) depends on the aircraft type but is limited by the length of the wiring harness and bowden cable length to wastegate. - After switching on the TCU, ensure that the automatic self check of the servo motor is performed.
  • Page 383 BRP-Rotax Maintenance Manual If this aid is not at your disposal, an engine test run must be performed. See corresponding Maintenance Manual (Line Maintenance) for the respective engine type 914 Series. ▲ WARNING: If a check reveals shortcomings, the engine must not be taken into operation until the cause is found and rectified.

  • Page 384: 8) Circuit Breaker For Servo Motor

    BRP-Rotax Maintenance Manual 3.1.2.8) Circuit breaker for servo motor See Fig. 76-49. The location of the circuit breaker (1) depends on the aircraft type, but is limited by the length of the wiring harness. ■ CAUTION: The circuit breaker is not included in the delivery range of the engine.

  • Page 385: 9) Three-Way Solenoid Valve

    BRP-Rotax Maintenance Manual 3.1.2.9) Three-way solenoid valve See Fig. 76-50 The 3-way solenoid valve (1) is installed on the engine suspension frame or directly on airbox on newer engines. ■ CAUTION: In the event of physical damage, mechanical defects or readings outside tolerance, replace the part without delay.

  • Page 386: Wiring Diagrams

    BRP-Rotax Maintenance Manual 3.2) Wiring diagrams 3.2.1 Engine external (on the 914 Series) See Installation Manual for the respective engine type 914 Series, latest issue. 76-00-00 Effectivity 914 Series Edition 1 / Rev. 0 page 54 May 01/2007...

  • Page 387: Form Sheets

    BRP-Rotax Maintenance Manual 4) Form Sheets 06750 Fig. 76-52 76-00-00 Effectivity 914 Series Edition 1 / Rev. 0 page 55 May 01/2007...
  • Page 388 BRP-Rotax Maintenance Manual NOTES 76-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 56 May 01/2007...
  • Page 389 3.3.2) Muffler: ................78-00-00 / 11 3.3.3 Turbocharger ..............78-00-00 / 12 3.4) Assembly of the complete exhaust system (on the 912 Series) ... 78-00-00 / 15 3.5) Assembly of the complete exhaust system incl. turbocharger (on the 914 Series) ............... 78-00-00 / 15 3.6) owden cable, rope sheave and spring for wastegate control...
  • Page 390 BRP-Rotax Maintenance Manual NOTES 78-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 2 May 01/2007...

  • Page 391: Systems Description

    2.1) Exhaust system (on the 912 Series) On ROTAX engines of the 912 Series, the exhaust system is not included in the ROTAX range of delivery. The engine is supplied only with the 4 exhaust sockets on the cylinder head.
  • Page 392 BRP-Rotax Maintenance Manual The turbine transforms the energy of the hot exhaust gases and drives a blower which aspirates ambient air and transfers it precompressed via the carburetors into the cylinders. The sole operational connection between engine and turbo is the air and exhaust stream.

  • Page 393: Connections For Instrumentation

    The temperature display device is connected via NiCrNi control lines. On 912 Series: The manufacturer of the exhaust system must attach or provide the connections M8x1 for installation of the metalsheathed thermocouples, part no. 966370, in the exhaust bends.
  • Page 394 BRP-Rotax Maintenance Manual NOTES 78-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 6 May 01/2007...

  • Page 395: Maintenance

    The following sections describe maintenance procedure for engines of the 912/914 Series above and beyond the maintenance and special checks, see corresponding Maintenance Manual (Line Maintenance) for the respective engine type, 912 Series or 914 Series, and the systems descriptions given hitherto. The description is subdivided into subsections and descriptions of the function of the various systems.
  • Page 396 BRP-Rotax Maintenance Manual Support the complete unit of exhaust - turbocharger - manifold, remove the tension clamp and take off the complete unit. Remove the distance sleeve (10) 10.5/17/15 from the engine suspension frame attachment. ◆ NOTE: If necessary, remove the Bowden cable (11) for wastegate control.
  • Page 397 BRP-Rotax Maintenance Manual Exhaust manifold: ◆ NOTE: There is no need to disassemble the complete unit of muffler - turbocharger - exhaust manifold for the removal of the muffler bracket. The exhaust manifold (22) is directly attached to the turbine housing by means of allen screws (23) M8x25 and nuts (24) and to the holder (26) by means of allen screw M8x50 (25).
  • Page 398 BRP-Rotax Maintenance Manual Zyl. Fig. 78-3 Cyl. Zyl. Cyl. Zyl. Cyl. Zyl. Cyl. 08001 78-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 10 May 01/2007...

  • Page 399: Inspection Of The Exhaust System And Turbocharger Components

    BRP-Rotax Maintenance Manual 3.3) Inspection of the exhaust system and turbocharger components (only on the 914 Series) See Fig. 78-3 Visual inspection of all components. ■ CAUTION: Because of the high thermal stress, inspect the complete exhaust system especially for crack formation.

  • Page 400: Turbocharger

    Visual inspection of the turbocharger. ◆ NOTE: The turbocharger is handled as a complete unit, i.e. no spare parts are available from BRP-Rotax. In the event of damage, the complete unit has to be replaced. Inspect face of turbine inlet.
  • Page 401 BRP-Rotax Maintenance Manual The bearings are tested by means of the pressure drop measuring method. ■ CAUTION: For this test, compressed air at approx. 2 bar (29 p.s.i) and a testing device are needed. Consisting of: pressure gauges orifice jet (inner diameter = 1 mm (.039 in.) / length = 3 mm (.12 in.)
  • Page 402 BRP-Rotax Maintenance Manual Fig. 78-5 07732 78-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 14 May 01/2007...

  • Page 403: Assembly Of The Complete Exhaust System (On The 912 Series)

    BRP-Rotax Maintenance Manual 3.4) Assembly of the complete exhaust system (on the 912 Series) ■ CAUTION: For assembly, observe the exhaust system and aircraft manufacturers´ instructions. 3.5) Assembly of the complete exhaust system incl. turbocharger (on the 914 Series) See Figs. 78-3, 78-6 and 78-7.
  • Page 404 BRP-Rotax Maintenance Manual Engine suspension frame / exhaust system assembly / exhaust bends Screw the engine suspension frame (1) to the engine housing with the lock washers and the allen screw M10x110 (3) and M10x35 (4). See Fig. 71-10 and 71-11 in 71-00-00.
  • Page 405 BRP-Rotax Maintenance Manual Re-establish attachment (9) turbocharger bracket engine suspension frame (not supplied with engine). Tightening torque as specified by the aircraft manufacturer. Tightening torque of the M10 screws = 15 Nm (133 in.lb). Reconnect the two oil lines for turbocharger on the oil pump.
  • Page 406 BRP-Rotax Maintenance Manual After completion of installation as described, all the screw connec- tions on the turbocharger bracket, exhaust manifold, exhaust bends and the tension clamp must be tightened to the specified torques. See Fig. 78-3 Tightening torque: Allen screws (8) M10x50 turbocharger bracket 15 Nm/ 133 in.lb...

  • Page 407: Owden Cable, Rope Sheave And Spring For Wastegate Control

    BRP-Rotax Maintenance Manual 3.6) Bowden cable, rope sheave and spring for wastegate control (on the 914 Series) See Fig. 78-9 3.6.1) Disassembly Remove tension spring (1) with a suitable tool and cut wire (2) of the Bowden cable. Loosen set screw of nipple (3) and pull Bowden cable out of the cable retainer (4).

  • Page 408: 2) Checking Of The Components

    ■ CAUTION: Renew bowden cable if damaged. See the correspond- ing Maintenance Manual (Line Maintenance) for the respective engine type, 912 Series or 914 Series. Check spring engagement holes (11) for wear. ■ CAUTION: On older engine versions, observe SB-914-008.
  • Page 409 BRP-Rotax Maintenance Manual If the cable retainer has been removed at disassembly, apply LOCTITE 648 on cable retainer (4) and press it into servo motor housing. Fit Bowden cable to wastegate lever with pin (7) and cotter pin (6). Feed Bowden cable through flexible conduit (and integrated adjusting screw) (14).
  • Page 410 BRP-Rotax Maintenance Manual NOTES 78-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 22 May 01/2007...
  • Page 411 3.1.2) Oil pump disassembly ............79-00-00 / 14 3.1.3) Oil pump checking ............79-00-00 / 15 3.1.4) Oil pump assembly (on 912 Series) ......... 79-00-00 / 18 3.1.5) Oil pump assembly (on 914 Series) ......... 79-00-00 / 19 3.2) Pressure check valve (only on 914 Series) ........79-00-00 / 20 3.3) Oil sump (only on 914 Series) ............
  • Page 412 BRP-Rotax Maintenance Manual NOTES 79-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 2 May 01/2007...

  • Page 413: Systems Description

    Lubrication system See Figs. 79-1 and 79-2. ROTAX engine types of the 912/914 Series are equipped with a dry sump forced lubrication and a main oil pump with integrated pressure regulator. The ROTAX 914 Series has an additional suction pump for the turbocharger oil circuit.
  • Page 414 BRP-Rotax Maintenance Manual 912 Series Fig. 79-1 09160 914 Series Fig. 79-2 05017 79-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 4 May 01/2007...

  • Page 415: Main Oil Pump (Engine Lubrication Circuit)

    BRP-Rotax Maintenance Manual 2.2) Main oil pump (Engine lubrication circuit) See Fig. 79-3 The trochoid oil pump sucks the engine oil out of the oil tank (1) via line (2). The oil passes through the oil cooler (3) fitted on the suction side via the oil line (4) to the oil pump rotor (5) (main oil pump), which is driven by the oil pump shaft (6).
  • Page 416 BRP-Rotax Maintenance Manual On the ROTAX 912/914 Series, which is equipped with a hydraulic governor, the governor (35) is supplied with the required forced oil via oil line (33). From the governor flange (34), the oil flows to the gear pump in the governor, which raises the pressure to approx.
  • Page 417 BRP-Rotax Maintenance Manual 912 Series 914 Series Fig . 79-3 00130 79-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 7 May 01/2007...

  • Page 418: Suction Pump (Turbocharger Oil Circuit, Only On 914 Series)

    BRP-Rotax Maintenance Manual 2.3) Suction pump (turbocharger oil circuit, only on 914 Series) See Fig. 79-4 The suction pump (11) is of the same design as the main oil pump (12) and sits on the extended common pump shaft (15).
  • Page 419 BRP-Rotax Maintenance Manual zum hydr. Verstellregler 912 Series (optional) to hydr. governor 914 Series Fig . 79-4 Ölzulauf oil inlet zum Öltank to oil tank Legend to Fig. 311: (1) Turbocharger (2) Pressure oil line (turbocharger) (3) Pressure valve (4) Valve housing (5) Pressure spring (6) Ball ø...

  • Page 420: Magnetic Plug

    Maintenance Manual 2.4) Magnetic plug See the corresponding Maintenance Manual (Line Maintenance) for the respec- tive engine type, 912 Series or 914 Series. 2.5) Drain plug See the corresponding Maintenance Manual (Line Maintenance) for the respec- tive engine type, 912 Series or 914 Series.

  • Page 421: Maintenance

    The following sections describe maintenance procedure for engines of the 912/914 Series above and beyond the maintenance and special checks, see corresponding Maintenance Manual (Line Maintenance) for the respective engine type, 912 Series or 914 Series, and the systems descriptions given hitherto. The description is subdivided into subsections and descriptions of the function of the various systems.
  • Page 422 BRP-Rotax Maintenance Manual 912 Series Fig. 79-5 07062 79-00-00 Effectivity 912 Series Edition 1 / Rev. 0 page 12 May 01/2007...
  • Page 423 BRP-Rotax Maintenance Manual 914 Series Fig. 79-6 07734 79-00-00 Effectivity 914 Series Edition 1 / Rev. 0 page 13 May 01/2007...

  • Page 424: 2) Oil Pump Disassembly

    The adjusting shim is only fitted if required to reach the specified oil pressure. On the 912 Series: Remove the oil pump cover (22), needle pins (23), pressure inner and outer rotor (24) and O-ring 46x3 (25). Take out needle pin (26) and pull out oil pump shaft (30) with pressed in drive pin (31).
  • Page 425 BRP-Rotax Maintenance Manual 3.1.3) Oil pump checking See Figs. 79-7, 79-8, 3179-9, 79-10, 79-11, 79-12 and 79-13. Visually check all components of oil pump. Check inside (1) of oil pump cover with a straightedge (2) for wear. Check all revolving rotors of pump. If there are noticeable furrows on mating faces of rotor inside (3) and revolving piston outside (4), replace both components.
  • Page 426 BRP-Rotax Maintenance Manual 912 Series 912 Series On new engine models On older engine models Fig. 79-7 Fig. 79-8 05156 05152 Fig. 79-9 00073 914 Series 00076 Fig. 79-10 79-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 16...
  • Page 427 BRP-Rotax Maintenance Manual Fig. 79-11 00076 Fig. 79-12 Fig. 79-13 0.01mm 4 5 6 00071 00074 79-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 17 May 01/2007...

  • Page 428: 4) Oil Pump Assembly (On 912 Series)

    BRP-Rotax Maintenance Manual 3.1.4) Oil pump assembly (on 912 Series) See Fig. 79-5 Lubricate bearing bore for pump shaft in oil pump housing with engine oil and install pump shaft (30). Push needle pin (26) 4x15.8 into the pump shaft (30), insert suction inner and outer rotor (24) and turn the pump shaft to check it.
  • Page 429 BRP-Rotax Maintenance Manual 3.1.5) Oil pump assembly (on 914 Series) See Fig. 79-6 Lubricate bearing bore for pump shaft in oil pump housing with engine oil and install pump shaft (30). Push needle pin (26) 4x15.8 into the pump shaft, insert oil pump piston with rotor (24) in main oil pump and turn pump shaft to check it.

  • Page 430: Pressure Check Valve (Only On 914 Series)

    BRP-Rotax Maintenance Manual 3.2) Pressure check valve (only on 914 Series) See Fig. 79-14. Remove banjo bolt (1) M8 with sealing rings (2) 8x13. ◆ NOTE: The valve housing (3) is only removed in the event of damage or for cleaning.

  • Page 431: Oil Sump (Only On 914 Series)

    BRP-Rotax Maintenance Manual 3.3) Oil sump (only on 914 Series) See Fig. 79-15 ◆ NOTE: The oil sump (1) is only removed in the event of damage or for cleaning. Remove tension spring from wastegate flap with a suitable tool.

  • Page 432: Oil Tank

    BRP-Rotax Maintenance Manual 3.4) Oil tank See Fig. 79-19 Detach oil lines. Remove banjo bolt (1) M10 and remove ring hose nipple (2) with sealing rings 10x14. See latest Maintenance Manual "Line Maintenance“ for the respective engine type. Fig. 79-16...

  • Page 433: Oil Lines (Steel Lines)

    BRP-Rotax Maintenance Manual 3.5) Oil lines (steel lines) See Figs. 79-17 and 79-18. The steel oil lines are only removed in the event of damage or for cleaning. Governor pressure oil line (1) to hydr. governor disassembly Remove the cable clamp (2) for cable support from the side of the gearbox.
  • Page 434 BRP-Rotax Maintenance Manual Reassembly of the lines in reverse order. ■ CAUTION: Pay attention that the lines are fitted free of stress and without scouring. Respect minimum distances, e.g. 2 mm (0.08 in.) from housing. ■ CAUTION: On the 914 Series, it is important to ensure that a shim distance ring (part no.

  • Page 435: Oil Lines

    BRP-Rotax Maintenance Manual 3.6) Oil lines ■ CAUTION: The oil lines not supplied with the engine must be maintained as per aircraft manufacturers specifications. In addition the following maintenance work should be performed: Clean oil feed line from oil tank to oil cooler and to oil pump and check visually.

  • Page 436: Purging Of Lubrication System

    See the corresponding Maintenance Manual (Line Maintenance) for the respec- tive engine type, 912 Series or 914 Series. ◆ NOTE: The engines of the 912 Series and 914 Series have several temperature control points. Refer to wiring diagram in Opera- tors Manual.

  • Page 437: 2) Oil Pressure Sensor

    The operating pressure must remain within the specified limits. If this is not the case, check the lubrication system (see corresponding Maintenance Manual (Line Maintenance) for the respective engine type, 912 Series or 914 Series.) oil pressure sensor indicating instrument...
  • Page 438 BRP-Rotax Maintenance Manual For sensor resistance see following graph showing sensor resistance over pressure. Compare pressure gauge with a calibrated instrument. ■ CAUTION: The graph resistance over pressure has been deter- mined, and is effective at the following conditions only.

  • Page 439: Wear Limits

    BRP-Rotax Maintenance Manual 4) Wear limits 0.01mm 4 5 6 07429 wear wear Reading new limit limit Description Readings 100% Oil pump Clearance main actual 0,00 0,05 0,20 0,13 pump (pump cover/ OP01 0,0000 0,0020 0,0079 0,0049 renewed rotor) Clearance suction...
  • Page 440 BRP-Rotax Maintenance Manual NOTES 79-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 30 May 01/2007...
  • Page 441 BRP-Rotax Maintenance Manual SECTION 80 ELECTRIC STARTER 1) Table of contents SECTION 80 ELECTRIC STARTER 1) Table of contents ..................80-00-00 / 1 2) Systems description ................. 80-00-00 / 3 2.1) Electric starter ................80-00-00 / 3 3) Maintenance ................... 80-00-00 / 5 3.1) Electric starter dismantling ............
  • Page 442 BRP-Rotax Maintenance Manual NOTES 80-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 2 May 01/2007...

  • Page 443: Systems Description

    BRP-Rotax Maintenance Manual 2) Systems description 2.1) Electric starter The electric starter is a DC motor with permanent magnets and carbon brushes. The gear-tooth system on the armature shaft is permanently engaged in the intermediate gear. During the startup process, the sprag clutch establishes a connection to the crankshaft via the intermediate gear and the free wheel gear.
  • Page 444 BRP-Rotax Maintenance Manual NOTES 80-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 4 May 01/2007...

  • Page 445: Maintenance

    The following sections describe maintenance procedure for engines of the 912/914 Series above and beyond the maintenance and special checks, see corresponding Maintenance Manual (Line Maintenance) for the respective engine type, 912 Series or 914 Series, and the systems descriptions given hitherto. The description is divided into subsections and descriptions of the function of the various systems.
  • Page 446 BRP-Rotax Maintenance Manual 3.1.2) HD starter See Fig. 80-2 Remove the 2 hex. nuts M5 (1) with lock washers (2) and washers (3) from the rear side of the ignition cover (6). The electric starter (4) can be removed by releasing the tension clamp (5).

  • Page 447: 1) Standard Starter

    BRP-Rotax Maintenance Manual 3.2) Electric starter — disassembly 3.2.1) Standard starter See Fig. 80-3 Unscrew combined nut (23) and remove connector sheath (17) with O- ring (19). Pull bearing flange (1) off the starter housing (2). Carefully pull rotor bearing (3) a short way off the starter housing and press the positive carbon brush (23) with the connector sheath (17) out of the rotor bearing.
  • Page 448 BRP-Rotax Maintenance Manual 3.2.2) HD starter See Fig. 80-4 Unscrew combined nut (23) and remove connector sheath (17) with O- ring (19). Unscrew allen screw (24) M5 and pull bearing flange (1) off the starter housing (2). Carefully pull rotor bearing (3) a short way off the starter housing and press the positive carbon brush (23) out of the rotor bearing.

  • Page 449: Electric Starter - Inspection Of Individual Parts

    BRP-Rotax Maintenance Manual 3.3) Electric starter — inspection of individual parts See Figs. 80-3, 80-4, 80-5 and 80-6. ◆ NOTE: The following work steps apply to both starter models (HD and standard starter). After disassembly of starter, check the following parts:...
  • Page 450 BRP-Rotax Maintenance Manual Bearings Check bearing socket (13) and if necessary, replace the complete rotor bearing. Carbon brushes Carbon brushes (14) must move freely in their guides (15). Replace too short brushes (min. length 8 mm = 0.32 "). Check spring pressure, replace hot-run brush springs (16).

  • Page 451: Electric Starter - Reassembly

    BRP-Rotax Maintenance Manual 3.4) Electric starter — reassembly See Figs. 80-3, 80-4, 80-5, 80-6 and 80-7. ◆ NOTE: The following work steps apply to both starter models (HD and standard starter). Determine the required number of compensating shims (6) for the axial clearance, see dimension (ES08) of the rotor (5).

  • Page 452: Electric Starter - Installation

    BRP-Rotax Maintenance Manual 3.5) Electric starter — installation 3.5.1) Standard starter See Fig. 80-1 Lightly grease the centering bore (9) in the ignition housing (8). Push complete electric starter (6) with new O-rings (5) 4.7x1.4 and distance sleeves (4) into the ignition housing (8).
  • Page 453 BRP-Rotax Maintenance Manual 07449 ES08 07460 07555 07556 80-00-00 Effectivity 912/914 Series Edition 1 / Rev. 0 page 13 May 01/2007...
  • Page 454 BRP-Rotax Maintenance Manual 4) Wear limits ◆ NOTE: The wear limits apply to both configurations of the electric starter, standard and HD. 07205 wear wear Reading new limit limit Description Readings 100% Electric starter actual 28,0 27,5 Commutator ES03 1,102...
  • Page 456 Motornummer / Engine serial no. Flugzeugtype / Type of aircraft Flugzeugkennzeichen / Aircraft registration no. ROTAX® Vertriebspartner ROTAX® authorized distributor www.rotax-aircraft-engines.com ® and TM are trademarks of BRP-Rotax GmbH & Co. KG. © 2006 BRP-Rotax GmbH & Co. KG. All rights reserved.

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