Rotax 912 MAINTENANCE MANUAL

AIRCRAFT ENGINES
ref. no.: MML-912 | part no.: 899191

WARNING
Before starting any maintenance work, please read the Maintenance Manual,
as it contains important safety relevant onformation. Failure to do so may
result in personal injuries including death. Consult the original equipment
manufacturer´s handbook for additional instructions!
These technical data and the information embodied therein are the property of
BRP-Powertrain GmbH&Co KG, Austria, acc, BGBI 1984 no. 448, and shall not, without prior
written permission of BRP-Powertrain GmbH&Co KG, be disclosed in whole or in part to third
parties. This legend shall be included on any reproduction of these data, in whole or in part.
Copyright 2013 © - all rights reserved.
ROTAX® is a trade mark of BRP-Powertrain GmbH&Co KG. In the following document the
short form of BRP-Powertrain GmbH&Co KG = BRP-Powertrain is used.
Other product names in this documentation are used purely for ease of identification and
may be trademarks of the respective company or owner.
Approval of translation has been done to best knowledge and judgement - in any case the
original text in german language is authoritative.
BRP-Powertrain
MAINTENANCE MANUAL
Chapter: INTRO
GENERAL NOTE
Foreword Before carrying out maintenance work on the engine, read the Mainte-
nance Manual (Line Maintenance) carefully.
If any passages of the Manual are not clearly understood or if you have
questions, please contact an authorized Distribution or Service Center for
ROTAX-aircraft engines.
Chapter structure The structure of the Manual follows whenever it is applicable the struc-
ture of the ATA (Air Transport Association) standards. The aim is the
compatibility with the aircraft manufacturer documentation, i.e. they must
adapt these documentation to their standard.
The Maintenance Manual is subdivided into the following chapters:
Subject Chapter
Introduction Chapter INTRO
List of effective pages Chapter LEP
Table of amendments Chapter TOA
General note Chapter 00-00-00
Airworthiness limitations Chapter 04-00-00
Maintenance Chapter 05-00-00
Time limits Chapter 05-10-00
Scheduled maintenance checks Chapter 05-20-00
Unscheduled maintenance checks Chapter 05-50-00
Maintenance of the systems Chapter 12-00-00
Replenishing operating fluids Chapter 12-10-00
Scheduled maintenance Chapter 12-20-00
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NOTES
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Chapter: LEP
LIST OF EFFECTIVE PAGES
t chapter page date chapter page date
Title page 05-10-00 3 09 01 2012

INTRO 1 09 01 2012 4 09 01 2012
2 09 01 2012 5 09 01 2012
6 01 01 2013
LEP 1 01 01 2013 7 01 01 2013
2 01 01 2013 8 09 01 2012
TOA 1 01 01 2013 05-20-00 1 09 01 2012
2 09 01 2012 2 09 01 2012
3 01 01 2013 3 09 01 2012
4 09 01 2012 4 09 01 2012
00-00-00 1 09 01 2012 5 09 01 2012
2 09 01 2012 6 09 01 2012
3 09 01 2012 7 09 01 2012
4 09 01 2012 8 09 01 2012
5 09 01 2012 9 09 01 2012
6 09 01 2012 10 09 01 2012
7 09 01 2012 11 01 01 2013
8 09 01 2012 12 01 01 2013
9 09 01 2012 13 01 01 2013
10 09 01 2012 14 01 01 2013
11 09 01 2012 15 01 01 2013
12 09 01 2012 16 01 01 2013
13 09 01 2012 17 01 01 2013
14 09 01 2012 18 01 01 2013
15 09 01 2012 05-50-00 1 01 01 2013
16 09 01 2012 2 09 01 2012
04-00-00 1 09 01 2012 3 01 01 2013
2 09 01 2012 4 01 01 2013
5 09 01 2012
05-00-00 1 09 01 2012 6 09 01 2012
2 09 01 2012 7 09 01 2012
3 09 01 2012 8 09 01 2012
4 09 01 2012 9 01 01 2013
5 09 01 2012 10 09 01 2012
6 09 01 2012 11 01 01 2013
7 09 01 2012 12 01 01 2013
8 09 01 2012 13 01 01 2013
9 09 01 2012 14 01 01 2013
10 09 01 2012 15 01 01 2013
11 09 01 2012 16 01 01 2013
12 09 01 2012 17 01 01 2013
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05-10-00 1 09 01 2012 19 01 01 2013
2 09 01 2012 20 01 01 2013

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chapter page date chapter page date
05-50-00 21 01 01 2013 28 09 01 2012

22 01 01 2013 29 09 01 2012
23 01 01 2013 30 09 01 2012
24 01 01 2013 31 09 01 2012
25 09 01 2012 32 01 01 2013
26 09 01 2012 33 09 01 2012
34 09 01 2012
12-00-00 1 01 01 2013 35 09 01 2012
2 01 01 2013 36 09 01 2012
12-10-00 1 09 01 2012 37 09 01 2012
2 09 01 2012 38 09 01 2012
3 09 01 2012 39 09 01 2012
4 09 01 2012 40 09 01 2012
5 09 01 2012 41 09 01 2012
6 09 01 2012 42 09 01 2012
7 09 01 2012 43 09 01 2012
8 09 01 2012 44 09 01 2012
9 09 01 2012 45 09 01 2012
10 09 01 2012 46 09 01 2012
11 09 01 2012 47 09 01 2012
12 09 01 2012 48 09 01 2012
49 01 01 2013
12-20-00 1 01 01 2013 50 09 01 2012
2 09 01 2012 51 09 01 2012
3 09 01 2012 52 01 01 2013
4 09 01 2012 53 09 01 2012
5 01 01 2013 54 01 01 2013
6 09 01 2012 55 09 01 2012
7 01 01 2013 56 01 01 2013
8 09 01 2012 57 09 01 2012
9 01 01 2013 58 09 01 2012
10 09 01 2012 59 09 01 2012
11 01 01 2013 60 01 01 2013
12 01 01 2013 61 09 01 2012
13 09 01 2012 62 09 01 2012
14 09 01 2012 63 09 01 2012
15 01 01 2013 64 09 01 2012
16 09 01 2012 65 09 01 2012
17 09 01 2012 66 09 01 2012
18 09 01 2012 67 09 01 2012
19 09 01 2012 68 01 01 2013
20 09 01 2012 Rear page
21 09 01 2012
22 09 01 2012
23 09 01 2012
24 01 01 2013
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26 09 01 2012
27 09 01 2012

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Chapter: TOA
TABLE OF AMENDMENTS
Approval*
The technical content of this document is approved

under the authority DOA ref. EASA.21J.048
Note: THE APPROVAL IS GIVEN TO ALL CHAPTERS

EXCEPT THE AIRWORTHINESS LIMITATIONS
SECTION 04-00-00 WHICH IS SUBJECT TO
SPECIFIC APPROVAL OF THE EASA.
date of ap-
date of remark for date of
no. chapter page proval from signature
change approval issue
authorities
0 INTRO all 09 01 2012 DOA*

0 LEP all 09 01 2012 DOA*
0 TOA all 09 01 2012 DOA*
0 00-00-00 all 09 01 2012 DOA*
0 04-00-00 1 09 01 2012 EASA approved
0 05-00-00 all 09 01 2012 DOA*

0 05-10-00 all 09 01 2012 DOA*
0 05-20-00 all 09 01 2012 DOA*
0 05-50-00 all 09 01 2012 DOA*
0 12-00-00 all 09 01 2012 DOA*
0 12-10-00 all 09 01 2012 DOA*
0 12-20-00 all 09 01 2012 DOA*
1 LEP all 01 01 2013 DOA*

1 TOA 1, 3 01 01 2013 DOA*
1 05-10-00 6,7 01 01 2013 DOA*
1 05-20-00 11-18 01 01 2013 DOA*
1 05-50-00 1,3,4,9 01 01 2013 DOA*
11-24 01 01 2013 DOA*
1 12-20-00 1,5,7,9,11, 01 01 2013 DOA*
12,15,24 01 01 2013 DOA*
25,32,49, 01 01 2013 DOA*
52,54,56, 01 01 2013 DOA*
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NOTES
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TOA
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Chapter: TOA
SUMMARY OF AMENDMENTS
Content
Summary of the relevant amendments in this context, but makes no claim to
completeness.
Current date of
chapter page Comment
No. change
0 all all 09 01 2012 New Edition.

0 05-00-00 5 09 01 2012 Valid time.
0 05-10-00 5, 8 09 01 2012 Storage period of engine, Time limit for fuel pump.
0 05-20-00 17 09 01 2012 Smooth performance of the engine
0 12-20-00 22, 49 09 01 2012 Inspect rotary seal for leakage, compressed air
1 05-10-00 6,7 01 01 2013 Footnote number changed.

1 05-20-00 11 01 01 2013 Change of text.
12 01 01 2013 Change of 600 hr.
13 01 01 2013 Change of reference.
14 01 01 2013 Compression check changed to every 200 hr.
14 01 01 2013 Carburetor synchronization changed to mech. and
pneumatic synchronization.
15 01 01 2013 Float chamber assy. check changed to every 200 hr.
16 01 01 2013 Checking the propeller gearbox: footnotes added.
16 01 01 2013 Oil change: footnote added, reference changed.
16 01 01 2013 Check the oil tank: changed to every 200 hr.
17 01 01 2013 Engine test run: Reference added.
18 01 01 2013 Change of text.
1 05-50-00 1 01 01 2013 Change of text.
3 01 01 2013 Chapt. 1.1: change of text.
12-23 01 01 2013 Change of chapter number.
13 01 01 2013 Cylinder head temperature instead of coolant temper-
ature.
1 12-20-00 1,5,7 01 01 2013 Change of text.
9 01 01 2013 Text deleted.
24,25 01 01 2013 Graphic reference added. page 25 step 3 added.
52 01 01 2013 Change of text. possible foreign matter added
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68 01 01 2013 Checking the friction torque: formular added.

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NOTES
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MAINTENANCE MANUAL
Chapter: 00-00-00
GENERAL NOTE
Introduction This section describes this maintenance of engine type ROTAX 912
Series.
NOTES: The ROTAX 912 Series includes all engines such as the
912 A, 912 F, 912 S, 912 UL, 912 ULS and 912 ULSFR.
Table of contents This chapter of the Maintenance Manual contains general and safety
information concerning the operation of the aircraft engine.
Subject Page
General note page 3
Abbreviations and terms used in this Manual page 5
Conversion table page 8
Safety notice page 9
Safety information page 10
Instruction page 12
Maintenance Concept page 13
Technical documentation page 14
Use for intended purpose page 16
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1) General note
Purpose The purpose of this Maintenance Manual is to acquaint maintenance ser-
vice staff (iRMT) approved by the local aviation authorities with some
basic maintenance and safety information for service work.
Documentation For more detailed information regarding, maintenance, safety- or flight

operation, consult the documentation provided by the aircraft manufac-
turer and/or dealer.
For additional information on engines, maintenance or parts, you can
also contact your nearest authorized ROTAX-aircraft engine distributor.
ROTAX ROTAX Authorized Distributors for Aircraft Engines see latest Operators
Distributors Manual or on the Internet at the official Website
www.FLYROTAX.com.
Engine serial When making inquiries or ordering parts, always indicate the engine
number serial number, as the manufacturer makes modifications to the engine for
product improvement. The engine number (1) is on the ignition cover, on
the left, opposite the electric starter. See Fig. 1.
Cyl. 1 Cyl. 3
Cyl. 2 Cyl. 4
Fig. 1 07902
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NOTES
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2) Abbreviations and terms used in this Manual

Abbreviations
Abbreviation Description
* Reference to another section
center of gravity
The drop symbol indicates use of sealing agents, adhesives or
lubricants. (only in the Illustrated Parts Catalog)
°C Degrees Celsius (Centigrade)
°F Degrees Fahrenheit
rpm Revolutions per minute
912 A see OM (Type designation)
912 F see OM (Type designation)
912 S see OM (Type designation)
912 UL see OM (Type designation)
912 ULS see OM (Type designation)
914 F see OM (Type designation)
914 UL see OM (Type designation)
A Ampere
Ah Ampere hour
A/C Aircraft
A/F Across-flat dimension
ASB Alert Service Bulletin
ACG Austro Control GmbH
API American Petrol Institute
ASTM American Society for Testing and Materials
ATA Air Transport Association
CAN/CGSB Canadian General Standards Board
CSA Constant Speed Actuator
CW Clockwise
CCW Counter-clockwise
DCDI Dual Capacitor Discharge Ignition
DOT Department of Transport
DOA Design Organisation Approval
EASA European Aviation Safety Agency
IM Installation Manual
ECU Engine Control Unit
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EGT Exhaust Gas Temperature

INTRO Introduction
EMS Engine Management System

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MAINTENANCE MANUAL
EN European Norm
IPC Illustrated Parts Catalog
FAA Federal Aviation Administration
FAR Federal Aviation Regulation
OM Overhaul Manual
hr. hours
OM Operators Manual
IFR Instrument Flight Rules
iRMT independent ROTAX Maintenance Technician
TOC Table of Contents
ISA International Standard Atmosphere
kg kilograms
AD Airworthiness Directive
MS magneto side
MON motor octane number
N new part (only Illustrated Parts Catalog)
nB as necessary (only Illustrated Parts Catalog)
n.a. not available
NDT non-destructive testing
Nm newton meter
POA Production Organisation Approval
PSU power supply unit
PTO Power Take Off
Rev. Revision
ROTAX is a trade mark of BRP-Powertrain GmbH & Co KG
RON Research Octane Number
RV Record of Revisions
s.v. still valid (only IPC)
S/N Serial Number
SB Service Bulletin
SI Service Instruction
SL Service Letter
SMD Surface Mounted Devices
TBO Time Between Overhaul
TC Type Certificate
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part no. Part number

TSNP Time Since New Part
TSO Time Since Overhaul

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V Volt
VFR Visual Flight Rules
LEP List of Effective Pages
W Watt
MM Maintenance Manual
XXX shows the serial component number
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2.1) Conversion table
Units of length: Units of power:

1 mm = 0.03937 in 1 kW = 1.341 hp
1 in = 25.4 mm 1 hp = 0.7457 kW
1 ft = 12 in 1 kW = 1.3596 PS
= 0.3048 m 1 PS = 0.7355 kW
Units of area: Units of temperature:

1 cm2 = 0.155 sq in (in2) K = °C - 273,15
1 sq in (in2) = 6.4516 cm2 °C = (°F - 32) / 1,8
°F = (°C x 1.8) + 32
Units of volume: Units of velocity:

1 cm3 = 0.06102 cu in (in3) 1 m/s = 3.6 km/h
1 cu in (in3) = 16.3871 cm3 (in3) 1 ft/min = 0.3048 m/min
1 dm3 = 1 l = 0.00508 m/sec
1 dm3 = 0.21997 gal (UK) 1 m/s = 196.85 ft/min
1 gal (UK) = 4.5461 dm3 1 kt = 1.852 km/h
1 dm3 = 0.26417 gal (US) 1 km/h = 0.53996 kn
1 gal (US) = 3.7854 dm3
Units of mass: spec. fuel consumption:

1 kg = 2.2046 lb 1 g/kWh = 0.001644 lb/hph
1 lb = 0.45359 kg 1 lb/hph = 608.277 g/kWh
Density: Units of torque:

1 g/cm3 = 0.016018 lb/ft3 1 Nm = 0.737 ft lb
1 lb/ft3 = 62.43 g/cm3 = 8.848 in lb
1 ft lb = 1.356 Nm
1 in lb = 0.113 Nm
Units of force: Cable cross-section:

1 N = 0.224809 lbf Conversion table - Wire Gauge:
1 lbf = 4.4482 N AWG-mm2
Units of pressure:
AWG 4 6 8 10 12 14 16 18 20
1 Pa = 1N/m2
1 bar = 100 000 Pa/1000 hPa/ mm2 21 13 8.4 5.3 3.3 2.1 1.3 0.8 0.52
100 kPa
1 bar = 14.5037 lbf/in2 (psi)
1 lbf/in2 (psi) = 0.0689 bar
1 in Hg = 33.8638 hPa
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3) Safety notice
General note Although the reading of such information does not eliminate the hazard,
understanding the information will promote its correct use. Always use
common workshop safety practice.
The information and components-/system descriptions contained in this
Manual are correct at the time of publication. BRP-Powertrain maintains a
policy of continuous improvement of its products without imposing upon
itself any obligation to install them on its products previously manufac-
tured.
Revision BRP-Powertrain reserves the right at any time, and without incurring obli-
gation, to remove, replace or discontinue any design, specification, fea-
ture or otherwise.
Measure Specifications are given in the SI metric system with the USA equivalent
in parenthesis.
Symbols used This Manual uses the following symbols to emphasize particular informa-
tion. This information is important and must be observed.
Identifies an instruction which, if not followed,
 WARNING
WARNUNG may cause serious injury including the possibility
of death.
Identifies an instruction which, if not followed,

 CAUTION
WARNUNG may cause minor or moderate injury.
Denotes an instruction which, if not followed,

NOTICE
WARNUNG may severely damage the engine or other compo-
nent.
NOTES: Indicates supplementary information which may be

needed to fully complete or understand an instruc-
tion.
ENVIRONMENTAL NOTE
Environment note gives you tips and behaviors to environmental protec-
tion.
A revision bar outside of the page margin indicates a
change to text or graphic.
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3.1) Safety notice

General note This information relates to the preparation and use of ROTAX aircraft
engines and has been utilized safely and effectively by BRP-Powertrain.
However, BRP-Powertrain disclaims liability for all damage and/or injuries
resulting from the improper use of the contents. BRP-Powertrain requires
that any service be carried out and verified by a technician that has a cur-
rent iRMT reating.
See chap. 05-00-00 section 1.2)
Manual This Manual has been prepared as a guide to correctly service and main-
tain all ROTAX 912 aircraft engines.
This edition was primarily published to be used by aircraft mechanics who
are already familiar with all service procedures relating to ROTAX aircraft
engines.
This Manual uses technical terms which may be slightly different from the
ones used in the Illustrated Parts Catalog.
It is understood that this Manual may be translated into another language.
In the event of any discrepancy the German version prevails.
Warning It is your responsibility to be completely familiar with the safety instructions

including warnings and cautions described in this Manual. These warnings
and cautions advise of specific operating and servicing methods that, if not
observed, can cause a serious engine malfunction or cause the engine to
lose power in flight which can result in loss of life, injury or damage to
equipment.
It is, however, important to understand that these warnings and cautions
are not exhaustive. BRP-Powertrain could not possibly know, evaluate and
advise the user of all conceivable ways in which service might be done or
of the possible hazardous consequences of each way.
Safety instruc- In addition to observing the instructions in our Manual, general safety and
tion accident preventative measures, legal regulations and regulations of any
aeronautical authority must be observed.
Where differences exist between this Manual and regulations provided by
any authority, the more stringent regulation should be applied.
Illustration The content depicts parts and/or procedures applicable to the particular
product at its time of manufacture. It does not include dealer modifications,
whether authorized or not by BRP-Powertrain, after manufacturing the
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Locking devices Locking devices (e.g. locking tab, self-locking fasteners, etc.) must be
installed or replaced with new ones, where specified. If the efficiency of a
locking device is impaired, it must be replaced.
Torque wrench If not specified otherwise, the threads are not lubricat-
tightening NOTICE
WARNUNG ed when fastened.
Torque wrench tightening specifications must be strictly adhered to.
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3.2) Instruction
General note Engines require instructions regarding their application, use, operation,
maintenance and repair.
Technical documentation and directions are useful and necessary comple-
mentary elements for personal instruction, but can by no means substitute
theoretical and practical instructions.
These instructions should cover explanation of the technical context,
advice for operation, maintenance, use and operational safety of the
engine.
Safety notice In this technical Manual passages concerning safety are especially
marked. Pass on safety warnings to other users!
Accessories This engine must only be operated with accessories supplied, recom-
mended and released by BRP-Powertrain. If the motor is equipped by
extra accessories it must be provided (and proven) that the engine under
all operating conditions comply with the limits prescribed by ROTAX.
Spare parts Spare parts must meet with the requirements defined
NOTICE
WARNUNG by the engine manufacturer. This is only warranted by
use of GENUINE ROTAX spare parts and/or accesso-
ries (see IPC) or suitable equivalent in the manufactur-
er’s opinion otherwise, any limited warranty by BRP-
Powertrain is null and void (see Warranty Conditions).
Spare parts are available at the authorized ROTAX
Distribution- and Service Center.
Any warranty by BRP-Powertrain becomes null and
void if spare parts and or accessories other than
GENUINE ROTAX spare parts and/or accessories are
used (see latest Warranty Conditions).
Tools In principle use only tools and appliances which are ei-
NOTICE
WARNUNG ther cited in the Manual or in the Illustrated Parts Cat-
alog.
Standstill After engine standstill (longer than 2 months) observe without fail the
instructions for engine “out of use”. Protect fuel- and carburetor system
against contamination.
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Returning When returning the engine or its components (e.g. propeller gearbox) to
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repair company, ensure that the necessary documentation (log book,

maintenance records etc.) are enclosed.
3.3) Maintenance Concept

General note The maintenance functions detailed in this Manual fall into two catego-
ries:
- Maintenance I (Line Maintenance)
- Maintenance II (Heavy Maintenance)
Repairs beyond the levels detailed in this Manual are not recommended
as maintenance functions and must be done by an authorized overhaul
facility.
Maintenance I Chapter 00,05 and 12

(Line Mainte-
nance)
The scope of line maintenance consists of removal, installation and
adjustment of engine components (including part wear). All procedures in
this Manual are to be considered line maintenance.
NOTES: Where applicable, you will be referred to the Heavy Main-
tenance Manual for work above and beyond line mainten-
nace.
Maintenance II separate Manual

(Heavy Mainte-
nance)
Maintenance Manual II details removal, installation and repair of compo-
nents or parts normally considered beyond the capabilities of the "Line
Maintenance".
NOTES: This Manual can only be used in combination with Main-
tenance Manual I (Line Maintenance), as it builds up on it.
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3.4) Technical documentation

General note These documents form the instructions ensuring continued airworthiness of
ROTAX aircraft engines.
The information contained is based on data and experience that are considered
applicable for authorized mechanics (iRMT) under normal conditions.
Due to the fast technical progress and fulfilment of particular specifications of the
customers it may occur that existing laws, safety prescriptions, constructional
and operational regulations cannot be transferred completely to the object
bought, in particular for special constructions, or may not be sufficient.
Documentation - Installation Manual

- Operators Manual
- Maintenance Manual (Line and Heavy Maintenance)
- Overhaul Manual
- Illustrated Parts Catalog
- Alert Service Bulletin
- Service Bulletin
- Service Instruction
- Service Letter
Status The status of the Manuals can be determined with the aid of the table of
amendments. The first column indicates the revision state. This figure
should be compared with the revision provided on ROTAX-WebSite:
www.FLYROTAX.com.
Amendments and current versions can be downloaded free of charge.
Replacement Furthermore the Manual is constructed in such a way that single pages
pages can be replaced instead of the complete document. The list of effective
pages is given in the chapter LEP. The particular edition and revision num-
ber is given on the footer of each page.
Reference This Manual for maintenance is only part of the Technical

NOTICE
WARNUNG Documentation and will be supplemented by the respective
Operators Manual, Installation Manual, Overhaul Manual
and Illustrated Parts Catalog.
Pay attention to references to other documentation, found in
various parts of this Manual.
Any reference to a document refers to the latest edition issued by
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Illustrations The illustrations in this Manual are mere sketches and show a typical
arrangement. They may not represent in full detail or the exact shape of
the parts which have the same or similar function. Therefore deduction of
dimensions or other details from illustrations is not permitted.
NOTES: The Illustrations and Documents in this Manual are stored
in a document data file/graphic data file and are provided
with a consecutive irrelevant number.
This number (e.g. 00277) is of no significance for the con-
tent.
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3.5) Use for intended purpose

General note Explosion hazard.
 WARNING
WARNUNG Bursting off parts can cause serious injuries. Never run
the engine without propeller.
Use The engine ROTAX 912 A/F/S is intended for use in certified aircraft. In
case of doubt the regulations of the national authorities or the respective
sportive federations have to be observed.
Certified engine Certified aircraft engine ROTAX 912 A/F/S is tested as per aeronautical
standards for safety and time between overhaul. It was developed to con-
form to the latest technological standards and rigorously tested.
Non certified en- Engine ROTAX 912 UL/ULS/ULSFR is not certified. These engines have
gine not received any aeronautical standards or regulatory safety or durability
testing, and conform to no aircraft standards. These engines are for use in
experimental, uncertificated aircraft and vehicles only in which an engine
failure will not compromise safety.
NOTES: These engines are technically equivalent to certified en-
gines and have been manufactured by BRP-Powertrain us-
ing the same quality assurance system.
Engine stop- The operator assumes all risk of use, and acknowledges by this use that
page he/she knows this engine is subject to sudden stoppage.
Maintenance Use for intended purpose also includes observation of the operational,
and repair con- maintenance and repair conditions prescribed by the manufacturer. This is
ditions a crucial factor concerning the reliability of the engine and can increase
the durability of the engine.
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Chapter: 04-00-00
AIRWORTHINESS LIMITATIONS
Approval
THE AIRWORTHINESS LIMITATIONS SECTION IS APPROVED BY THE

EUROPEAN AVIATION SAFETY AGENCY (EASA) IN ACCORDANCE
WITH PART 21A.31(a)(3) AND FAR 33.4. ANY CHANGE TO EACH
MANDATORY REPLACEMENT TIME, INSPECTION INTERVAL, AND
RELATED PROCEDURE CONTAINED IN THIS AIRWORTHINESS
LIMITATIONS SECTION MUST ALSO BE APPROVED.
date of ap-
date of remark for date of
no. chapter page proval from signature
change approval issue
authorities
1 04-00-00 all 09 01 2012 EASA approved
Introduction This chapter 04-00-00 provides information about “Airworthiness Limita-

tions“.
Airworthiness - NONE
Limitations
For the ROTAX type engine 912 Series the airworthiness limitations are
not applicable.
NOTE: Regarding engine operating limitations see the relevant chapter
“limits of operation“ in the relevant Operators Manual.
Maintenance checks and replacement of defined components
are required on this engine! These procedures are descriped in
chapter 05 and are a required by the authority in order to ensure
the Continued Airworthiness!
See chapt. 05-00-00.
Continued Air- Scheduled inspections of the engine including replacement and overhaul
worthiness of defined components are required in order to ensure the Continued Air-
worthiness of ROTAX aircraft engines.
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Chapter: 05-00-00
MAINTENANCE
Introduction The information given in the Maintenance Manual is based on data and
experience which are considered to be applicable for a skilled aviation
mechanic under normal working conditions
Table of contents In this chapter the maintenance of engine ROTAX 912 Series is
described. The description is subdivided into sections and description of
function of the various systems. Some overlapping maintenance instruc-
tions are treated as generally valid information at the beginning of this
section.
Subject Page
Maintenance page 3
General note page 3
Authorized personnel page 4
Procedure notes page 6
Trouble shooting page 8
Consumable materials page 9
Acceptable methods page 12
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1) Maintenance
1.1) General note
Safety notice Non-compliance can result in serious injuries or death!
 WARNING
WARNUNG Besides our instructions in the documentation sup-
plied, also respect the generally valid safety and acci-
dent preventive directives and legal regulations.
Procedures and The procedures and limits in this Manual constitute the manufacturers
limits official recommendation for engine maintenance and operation.
Instruction The guidelines given in the Maintenance Manual are useful and neces-
sary supplements to training. They, however, cannot substitute competent
theoretical and practical personal instruction.
Modifications Non-authorized modifications as well as the use of components and aux-

iliary components not corresponding to the installation instructions
exclude any liability of the engine manufacturer.
Parts and acces- We particularly emphasize that parts and accessories not supplied as
sories genuine BRP-Powertrain parts are not verified for suitability by BRP-Pow-
ertrain and thus are not authorized for use. Installation and/or use of such
products may possibly change or negatively influence the constructive
characteristics of the engine. For damages resulting from use of NON-
GENUINE ROTAX parts and accessories manufacturer refuses any liabil-
ity.
Special tools Maintenance of engines and systems requires special knowledge and
special tools. Use only the special tools recommended by BRP-Power-
train when disassembling and assembling the engine.
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1.2) Authorized personnel

General note It is a requirement that all organizations or individuals possess the
required special tooling. Technicians must have type-specific training and
keep a recurrent knowledge status for the level of work they intend to per-
form. Technicians may require accreditation from their local aviation
authority in addition to any BRP-Powertrain requirements.
Type-specific Any task outlined herein may be performed if the organization or individual
training has met the following conditions:
Requisite knowledge of the task as a result of:
- Type-specific training (for the applicable ROTAX aircraft engine) which is
approved by the national aviation authority and/or BRP-Powertrain.
or
- Experience in performing the task or
- Formal instruction from a BRP-Powertrain authorized training facility or
- Instruction by an authorized BRP-Powertrain Distributor representative.
Including:
- Suitable work environment to prevent contamination or damage to engine parts or
modules.
- Suitable tools and fixtures as outlined in the ROTAX Maintenance Manual.
- Reasonable and prudent maintenance practices are utilized.
- And the Requirements of the applicable regulatory authority regarding mainte-
nance procedures are met.
Information Maintenance organizations and individuals are encouraged to contact

BRP-Powertrain through its worldwide distribution network for information
and guidance on any of the tasks outlined herein.
See chap. 00-00-00 section: 3.4).
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Type-specific
training Type-specific training:
- Independent ROTAX Maintenance Technician (iRMT) training can be obtained
from a ROTAX approved training organization. Courses are available in various
levels to suit the requirements of work the technician needs to perform. Each rating
is valid for a 2 year period.
Valid time ROTAX iRMT specialty ratings are valid for a 2 year period after initial
instruction. Recurrent training is required after 2 years to maintain a cur-
rent status. In order to be eligible for the renewal program training, the
technician must be able to show and declare that they have been working
on ROTAX engines during the past 2 years.
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1.3) Procedure notes

General note Non-compliance can result in serious injuries or death!
 WARNING
WARNUNG When carrying out maintenance and service work, re-
spect without fail the safety regulations.
Ignition “OFF“ Non-compliance can result in serious injuries or death!

 WARNING
WARNUNG This precautionary measure serves to avoid any inju-
ries in case of an unintentional start of the engine.
Principally ensure the following at each maintenance
event
- Ignition “OFF“ and system grounded,
- Disconnect battery
and secure engine against unintentional operation.
Ignition “ON“ Risk of electric shock!

 WARNING
WARNUNG The ignition is switched on, as long as the ground-ca-
ble (P lead) is not properly connected to ground.
At maintenance work which requires ignition “ON“ and battery connected,
take care of the following:
- Secure the propeller against unintentional turning by hand and
- Secure and observe propeller zone
Handling of op- . Failure to comply with this instruction may cause se-
erating fluids  WARNING
WARNUNG vere burns or scalding!
Hot engine parts!
Always allow the engine to cool down to ambient tem-
perature before starting work.
At maintenance of cooling-, lubricating and fuel system take care without
fail that no contamination, metal chips, foreign material and/or dirt enters
the system.
Disassembly At disassembly of the engine, mark the components as necessary to avoid

any mix-up. Take care of these marks, don’t ruin them.
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Tool In order to avoid mechanical damages, never loosen

NOTICE
WARNUNG or tighten screws and nuts with pliers but only with the
specified tools.
Safety wiring If during disassembling/reassembling the removal of a

NOTICE
WARNUNG safety item (e.g. safety wiring, self-locking fastener,
etc.) should be necessary, it must be always replaced
by a new one.
Cleaning of parts All metall and synthetic parts are generally washed
NOTICE
WARNUNG with suitable cleaning agents. Before using new and
unknown cleaning agents check the compatibility of
materials.
Removed parts Before re-using disassembled parts, clean, check and refit them as per
instructions.
Use clean screws and nuts only and inspect face of nuts and thread for
damage. Check the contact faces and threads for damages. In case of
doubt, use new screws and nuts.
Nuts Once loosened, always replace self-securing nuts.

Non-compliance can result in serious injuries or death!
 WARNING
WARNUNG Exactly observe the tightening torques for screws and
nuts. Overtightening or too loose connection could
cause serious engine damage.
Sealing rings, At reassembly of the engine, replace all sealing rings, gaskets, securing
O-rings elements, O-rings and oil seals.
Re-assembly Before re-assembly check components whether parts are missing. Only
use adhesives, lubricants, cleaning agents and solvents indicated in the
maintenance instructions. If not respected, damage may be the conse-
quence.
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1.4) Trouble shooting

General notes In the Operators Manual, possible problems are listed. At the same time, a
brief description of the necessary remedial action is given.
See chapter 4 in the Operators Manual for engine type 912 (Series).
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1.5) Consumable Materials

General note Use only the specified or technically equivalent ma-
NOTICE
WARNUNG terials from BRP-Powertrain for all maintenance work.
When handling chemicals, comply with all the custom-
ary regulations and specifications of the producer, in-
cluding the expiry date and instruction.
NOTES: To some extent product descriptions deviate in spite of
equivalent technical properties, i.e.: LOCTITE 221 and
LOCTITE 222. If necessary contact the manufacturer con-
cerning the comparability. In some cases information can
be obtained from the local authorized distributors and ser-
vice partners for ROTAX engines.
NOTES: Respect the manufacturers instruction concerning the cur-
ing time and the expire date of the particular surface seal-
ing compound.
The materials specified have been tested for a long time and are suitable
for all operating conditions indicated by the manufacturer.
No. part no. Description, Application Qty.
1 899785 LOCTITE 221 violet, 10 ml (0.003 gal
medium-duty screw securing agent (US))
2 897651 LOCTITE 243 blue, 10 ml (0.003 gal
medium-duty screw securing agent (US))
3 899788 LOCTITE 648, 5 ml (0.001 gal
high strength screw securing agent (US))
4 899789 LOCTITE 603 green, 10 ml (0.003 gal
oil-tolerant grouting product, high-strength (US))
5 898241 LOCTITE 480 black, 20 ml (0.005 gal
instant adhesive increased flexibility (US))
6 899784 LOCTITE 574 orange, 50 ml (0.013 gal
surface sealing compound (US))
7 n.a. LOCTITE 518 red,
surface sealing compound, can be used instead
LOCTITE 574
8 899791 LOCTITE 5910 black, 50 ml (0.013 gal
surface sealing compound, can be used instead (US))
LOCTITE 574 and LOCTITE 518
9 297434 LOCTITE Anti-Seize 8151, 50 g (0.11 lb)
for the prevention of fretting corrosion
10 297433 MOLYKOTE G-N, 100 g (0.22 lb)
Lubricating paste
11 897166 MOLYKOTE 44 medium, 100 g (0.22 lb)
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12 897330 Lithium-base grease or Dow Corning, 250 g (0.55 lb)
to prevent leakage current
13 897870 Filter oil 14.8 ml (0.004
for optimum filter efficiency and protection gal (US))
against moisture
14 297368 SILASTIC 732, 310 ml (0.082
multi-purpose one-component silicon-based gal (US))
sealing compound
15 897186 SILICONE HEAT CONDUCTION COMPOUND 150 g (0.33 lb)
Application of the heat conduction compound
will reduce heat transfer resistance. The grease-
like, temperature-resistant silicon compound fills
cavities between components and the cooling
element (e.g.: spark plug-cylinder head), which
otherwise do not contribute to heat conduction.
16 297711 PU-glue 310 ml (0.082
for shock absorption gal (US))
17 n.a. Multi-purpose grease LZ
Generally useable, neutrally colored multi-pur-
pose grease, water resistant and highly adher-
ent. Useable for temperatures from -35 °C to
+120 °C (-31 °F to +248 °F) and can be subject-
ed to mechanical loads.
18 n.a. Preservation oil
Requirements: The preservation oil has excel-
lent penetrating capabilities and reaches even
tiny gaps, it’s highly effective additives protect
against corrosion of metal surfaces.
19 n.a. Very fine emery cloth SR 4600 A - very fine
standard
Is sold by the meter and used for Manual remov-
al of smaller rust spots or oxidation, especially
for optimum ground connections. It is highly suit-
able for removing LOCTITE from surfaces or
threads to make them metallic clean. Before re-
applying LOCTITE, clean surfaces with ni-
trothinner or degreasing agent (CASTROL ZA
30 or OMV-SOFT SOL). When using solvents,
observe the safety regulations for persons and
environment.
20 898570 Screw securing paint 20 ml (0.005 gal
seals screws (US))
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21 n.a. Cleaning agents
Use only approved cleaning
NOTICE agents (e.g. kerosine, varsol,
etc.) for cleaning all metal
parts.
Do not use lye-based cold cleaner or degreasing
agents. Do not clean coolant or oil hoses with
aggressive solutions. Clean off sealing com-
pound residue with sealant remover.
Soak combustion chamber, piston and cylinder
head with cleaning agent and remove combus-
tion residues with a bronze brush. Very good re-
sults have been achieved with “Clenvex 2000“.
It is a solvent-cold cleaner, free of halogen, on
the basis of selected fuel fractions with tensides
and is biologically disposable.
Never use caustic or corrosive cleaning agents.
22 n.a. MICRONORM abrasive
This abrasive is suitable for local and gradual
very fine treatment of steel parts with rust film
(propeller shaft). The MICRONORM abrasive
contains no noxious matter, is approved by the
relevant authorities and guarantees optimum
cleaning. The granulates used are of sizes 40 to
60 µ. It is possible to achieve a surface rough-
ness of 0,5 to 1µ, which represents fine process-
ing of surfaces.
23 n.a. LOCTITE 7063
Degreasing fluid. For parts cleaning before appl-
cation of adhesives and sealants.
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1.6) Acceptable methods, techniques and practice

General note All general inspection, maintenance and repair has to be carried out in
accordance with Advisory Circular AC 43.13 from FAA.
Advisory Circu- This Manual "Advisory Circular" AC describes maintenance methods,

lar techniques and practice. These are recognized and authorized for inspec-
tion and repairs in non-pressurized areas for which there are no separate
maintenance and repair instructions.
Self-locking Self-locking nuts, cotter pins, tab washers and safety

NOTICE
WARNUNG wires must be replaced each time they have been re-
moved.
Respect without fail all additional indications regarding securing and seal-
ing means and lubrication of fixation elements. Adhere to specified tight-
ening torques.
Nut securing When using a self-locking nut, take care that the polyamide insert ring on
nuts according to DIN 985 as well as the securing element on nuts accord-
ing to DIN 980 is positioned towards outside.
Lock washer NOTES: When fitting lock washers, the curved-up ends (1) must
point towards the screw head or nut.
1 1
00144
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Chapter: 05-10-00
TIME LIMITS
Introduction These checks, related to limited periods of operation, are planned to help
avoid engine troubles by the use of preventive maintenance.
Table of contents This chapter of the Maintenance Manual contains general information
regarding TBO and time limits on rubber components.
Subject Page
Definition of terms page 3
Operating hours page 3
Time limits page 3
Life cycle page 3
General Overhaul (TBO) page 4
Purging the oil system page 4
Time limit page 5
Time limit for rubber parts page 8
Time limit for fuel pump page 8
Time limit for the coolant page 8
Annual inspection page 8
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1) Definition of terms
1.1) Operating hours
Definition All of the maintenance intervals, such as the 100 hr. inspection and the
engine TBO, relate to the number of operating hours of the engine.
The operating hours are defined as follows in order to prevent misunder-
standings and to ensure safety:
- All time during which the engine is running is counted towards the total
number of operating hours.
- The time is counted irrespective of the load factor of the engine, such
as idling or take-off power.
NOTES: A mechanical hour meter is directly coupled to the engine
speed, the readings may deviate considerably from those
given by electronic remitters (e.g. TCU, FlyDat). Mainte-
nance and overhaul intervals are always dictated by the
readings of the electronic hour meter.
- The planned inspections to be performed at certain intervals are based
on experience from long test runs and field observations. They are
intended as precautionary maintenance measures in order to ensure
continued trouble-free operation of the engine.
1.2) Time limit

Definition Time limits are predetermined time spans and intervals which are based
either on calendar intervals or the number of engine operating hours.
Once the time limits have been reached, the affected parts must either be
replaced for a general overhaul, or maintenance work must be per-
formed. These precautionary maintenance measures are designed to
avoid engine malfunctions or defects and ensure continued airworthiness
of the engine.
1.3) Life cycle

Definition The life cycle is always specified as an exact time span and is also
quoted in flight hours.
NOTES: Parts with a limited life cycle must be taken out of opera-
tion and overhauled if the specified time span or number
of flight hours is reached (whichever comes first).
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1.4) General overhaul (TBO)

Definition The time between overhauls (TBO) for all objects (such as the engine,
component assemblies, add-on components) is the approved length of
operation under normal operating conditions before it becomes mandatory
to send in these objects for an overhaul.
Normal operating conditions are the conditions which comply with the
manufacturer's and the aviation authority’s recommendations for the certi-
fication of airworthiness.
Maintenance of The TBO values approved by the relevant authorities are based on perfor-
operation mance tests and empirical values which have been gathered through
operation of the engine and are required for the acceptance and certifica-
tion of airworthiness. TBO values can be changed in response to possible
upgrade/expansion programs.
Legal obligation TBO values for the engine are always shown in operating hours and years.
to keep The user must record the operating hours in the engine log book.
1.5) Purging the oil system

General note Purging of the oil system is extremely important for operation and service
life of the engine and therefore the procedure must be followed meticu-
lously.
See latest installation manual Chapt. 79-00-00 “Purging the lubrication
system“.
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2) Time limit
General A general overhaul is due after a defined period of op-
NOTICE
WARNUNG eration or after a specified calendar life since initial
start of operation (whichever comes first).
The time limit for engine operation will be specified by the TBO.
After reaching After reaching this time limit, the engine has to be
this time limit NOTICE
WARNUNG shipped to an authorized ROTAX overhaul facility.
For an overhaul, the engine must be removed from the aircraft, be
cleaned, preserved and all openings to be closed to prevent entering of
contaminants.
Storage period of Observe the storage and preservation directives!

the engine
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 autho-
rized overhaul facility for inspection.
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Engine engine affected TBO

Type description engine S/N Time Between Overhaul
912 A up to and incl. 4,076.191 600 hr. or 10 years,
whichever comes first(1
912 A from 4,076.192 up to and in- 1000 hr. or 10 years,
cl. 4,410.065 whichever comes first (1
912 A from 4,410.857 2000 hr. or 15 years,
whichever comes first
912 F up to and incl. 4,412.585 1000 hr. or 10 years,

whichever comes first (1
912 F from 4,412.586 up to and in- 1200 hr. or 10 years,
912 F from 4,412.817 up to and in- 1500 hr. or 12 years,
912 F from 4,412.975 2000 hr. or 15 years,
912 S up to and incl. 4,922.776 1200 hr. or 10 years,

912 S from 4,922.777 up to and in- 1500 hr. or 12 years,
912 S from 4,923.890 2000 hr. or 15 years,
912 UL up to and incl. 4,152.666 600 hr. or 10 years,

912 UL from 4,152.667 up to and in- 1200 hr. or 15 years,
912 UL from 4,404.718 up to and in- 1500 hr. or 15 years,
912 UL from 4,409.716 2000 hr. or 15 years,
912 ULS up to and incl. 4,427.532 1200 hr. or 10 years,

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Engine engine affected TBO

Type description engine S/N Time Between Overhaul
912 ULS from 6,775.790 2000 hr. or 15 years,
912 ULSFR up to and incl. 4,429.714 1200 hr. or 10 years,

912 ULSFR from 4,429.715 up to and in- 1500 hr. or 12 years,
912 ULSFR from 6,775.790 2000 hr. or 15 years,
For the TBO of the specific engine type/version refer to the table below.
(1
Extension of the TBO is possible and will be specified by a Service Bul-
letin (SB) for the respective engine type. For extensions already effective
refer to the engine log book or release certificate.
Authorized ex- Extension or exceeding of the TBO by 5 % or 6 months is allowed which-

ceeding ever comes first.
Shipment The shipment to an authorized ROTAX overhaul facility must include the
following:
1 Engine log book.
2 Maintenance records of the engine (i.e. all maintenance check lists, and reports
of operation, of maintenance, of findings and of oil analyses).
3 The engine assembly as per supply volume. Additionally all added-on parts as
in the supply volume such as carburetors, filters, fuel pump, external generator,
sensors, ignition unit, electric starter, oil tank.
4 Indication of total engine operating hours (TSN) and where applicable, engine
operating hours since a previous overhoul (TSO).
NOTE: This information must be supplied to allow the service his-
tory of components to be traced.
5 Data about the type of aircraft used.
6 Useful remarks and observations concerning the engine.
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2.1) Time limit for rubber parts

General note This time limit must be followed independently and in
NOTICE
WARNUNG addition to the visual inspections (see chap. 05-20-00
section: 5.1)) of the respective components.
Time limit The following components and systems must be replaced every 5 years:
- venting hose of the carburetors
- all rubber hoses of the cooling system
- all rubber hoses of the fuel system (incl. Fuel pump and insulating flange, if this is
teflon hoses) fixed with fuel hoses.
- venting hose of the fuel pump
- all rubber hoses of the lubrication sys-
tem which are part of the engine supply
volume and if they are not in the mainte-
nance schedule of aircraft manufacturer
- carburetor sockets
- connecting hose of the air intake system
- diaphragm on both carburetors
- rubber hoses on compensating tube
- V-belt
2.2) Time limit for fuel pump

General note The fuel pump must be replaced every 5 years.
2.3) Time limit for the coolant

General note Coolant must be replaced as per manufacturers instructions, at the latest
during overhaul or when the engine is replaced.
2.4) Annual inspection

General note A 100 hr. inspection is to be carried out periodically after every 100 hours
of operation or every 12 months, whichever comes first.
See chap. 05-10-00 section: 2).
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Chapter: 05-20-00
SCHEDULED MAINTENANCE CHECKS
Introduction The owner and/or user is primarily responsible for the maintenance and
airworthiness of the engine. This includes compliance with all applicable
airworthiness directives.
This inspection protocol is not intended to be all-inclusive, for no such
protocol can replace the knowledge and experience of a certified aircraft
mechanic. As the party primarily responsible for the maintenance and air-
worthiness of the engine, the owner or user should only have the mainte-
nance work carried out by qualified engineers.
Documentation It is the responsibility of the owner and/or user to make sure that the air-
required craft mechanic performing the work on the engine has access to the pre-
vious Inspection Protocols and any other required documents.
regarding periodic maintenance and the maintenance check list.
Subject Page
Scheduled maintenance checks page 3
Unscheduled maintenance checks page 5
Visual inspection page 7
Maintenance schedule procedures page 9
Check list/Maintenance schedule page 11
Maintenance schedule page 13
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1) Scheduled maintenance checks

Definition This section lists the periodic inspections which must be carried out after
a specified periods of operation.
Intervals Periodic inspections are those which must be performed at 25, 100, 200,
600 hr. intervals in accordance with chapt. 05-20-00. section: 5.1).
This means for example that every 100 hr. of operation a 100 hr. check
must be carried out. Every 200 hr. of operation a 100 hr. and the addi-
tional checks for 200 hr. must be carried out.
Intervals - hours
2000
25 hr 100 hr 200 hr 300 hr 400 hr 500 hr 600 hr 700 hr to
hr
100 hr X X X X X X X X X
200 hr X X X
600 hr X
100 hr. - In order to demonstrate continued airworthiness, an engine must be

check inspected after every 100 hours of operation or 12 months.
- For the intervals between maintenance work, a tolerance of ±10 hr. is
permissible, but these tolerances must not be exceeded. This means
that if a 100 hr. check is actually carried out at 110 hr., the next check
will be due at 200 hr. ±10 hr. and not at 210 hr. ±10 hr.
- If maintenance is performed before the prescribed interval, the next
maintenance check is to be done at the same interval (e.g. if first
100 hr. check is done after 87 hours of operation, the next 100 hr.
check must be carried out after 187 hours of operation).
- If engine has less than 100 hours of operation during one year a
100 hr. check must be carried out. For the annual inspection a toler-
ance of ±2 months is given.
Special hr. check NOTES: This maintenance schedule contains a column for a 50 hr.
check. This check is recommended by the manufacturer
but not essential, with the exception of oil change when
operating with leaded AVGAS.
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25-hr. - In order to demonstrate continued airworthiness, an engine must be

check inspected after the first 25 hours of operation.
- The checks performed at the 25 hr. inspection are the same as for the
100 hr. inspection. This applies both to newly delivered engines and to
overhauled engines.
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2) Unscheduled maintenance checks

Operating limits An inspection of the engine must be performed if the operating limits of
exceeded the engine have been exceeded (e.g. overspeed, excessive temperature
etc.), or if unusual operating conditions have occurred during operation
(e.g. lightning strike). In such cases the engine must be inspected in
accordance with the applicable unscheduled maintenance checks. (See
chapter 05-50-00).
Recommends in- The manufacturer also recommends the following inspections whenever
spections maintenance is carried out (where not already prescribed by the airframe
manufacturer, as possible malfunctions could have negative effects on
engine operation.
part inspection possible danger
Engine cowling - for discoloring and warping. Danger of overheating
- re-tighten the exhaust fixation Leakage
Exhaust fixation on the cylinder head after the
first 2 hr. of operation.
- of the exhaust unit (where nec- Risk of fracture, wear.
Exhaust essary, replaced application of Smooth engine running.
LOCTITE Anti-Seize).
- of fuel filter on airframe side (for Engine to misfire. Power
foreign bodies, sealing material loss. Engine running too
Fuel filter
and loose fragmented material). lean (Engine malfunction
and damage).
- correct function. Insufficient fuel supply.
Engine running to lean
Electr. fuel pump
(Engine malfunction and
damage).
- acid concentration for each cell Starting problems
Battery Observe the manufacturers instruc-
tion.
- for oil contamination. Possible engine wear
Oil - analyse the oil (provides addi-
tional information on the condi-
tion of the engine).
- for damage. Danger of overheating
Radiators, Lines - check for discoloration - and
cracks.
- undamaged and runs true Engine damage, unusual
- carry out dynamically balancing vibrations
Propeller
including verification of propeller
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MAINTENANCE MANUAL
Cell-side air intake - as specified by the cell manu- See specifics of manufac-
system facturer turer.
(NACA intake)
Cell-side attach- - as specified by the cell manu- See specifics of manufac-
ment points of en- facturer turer.
gine suspension
- as specified by the cell manu- See specifics of manufac-
Throttle control
facturer turer.
- as specified by the cell manu- See specifics of manufac-
Governor
facturer turer.
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MAINTENANCE MANUAL
3) Visual inspection
General note The scope of a visual inspection generally includes, but is not necessarily
limited to, the following.
Moving Normal operating condition, accurate alignment, leak-tightness, cleanli-

parts ness, ease of movement, adjustment, mechanical stress, travel, catching,
extreme wear, cracks, corrosion, deformation and other visually evident
damage.
Parts Secure seating, surface condition, cleanliness, deformation, cracks in

welding seams or due to material fatigue or stress, corrosion and other
visually evident damage.
Fuel-, Air- and Oil Cracks, dents, kinks, required flexibility, collapsed lines/hoses, abrasion,
lines cleanliness, secure seating and other visually evident damage.
Wiring General cleanliness; loose, corroded or broken terminals; chafed, broken

or worn insulation; secure seating, heat damage and other visually evi-
dent damage.
Screws and Nuts Surface damage, secure seating, locking wire, securing paint and other
visually evident damage.
Filter Filters and screens must be inspected for contamination and potential
blockages, cleaned and replaced as required.
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NOTES
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BRP-Powertrain
MAINTENANCE MANUAL
4) Maintenance schedule procedures (maintenance check list)

Inspections All stated checks are visual inspections for damage and wear, unless oth-
erwise stated.
Specified period All listed work must be carried out within the specified period.
Maintenance Checks are carried out as per the maintenance check lists, where type
check lists and volume of maintenance work is outlined in key words. See chapter
05-20-00 section 5.1).
- The lists must be photocopied and filled out for each maintenance
check.
Extra inspections - The respective check (e.g. 100 hr. check) must be noted on the top of
each page of the maintenance check list.
- All the maintenance work carried out must be initialled in the "signa-
ture" area by the aircraft mechanic performing the task.
Maintenance re- After maintenance, the completed check lists must be entered in the
cords maintenance records. The maintenance must be confirmed in the log
book.
Discrepancies/re- All discrepancies and remedial action must be recorded in a report of

medial action findings to be generated and maintained by the company authorized to
carry out maintenance work. It is the responsibility of the aircraft operator
to store and keep the records.
Replacement of Replacement of equipment (e.g. fuel pump, governor....) and execution of

equipment SB (LTA) must be entered in the engine log book, stating
S/N, TSN and date.
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NOTES
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MAINTENANCE MANUAL
5) Check List/Maintenance Schedule
Identification
AIRCRAFT
Registration number
Aircraft make
Aircraft model and S/N
Time since new
Propeller
Propeller brand
Propeller model and S/N
Governor brand
Governor model and S/N
ENGINE
Engine type
Engine S/N
TSN (time since new)
TSO (time since overhaul)
Used operating fluids:
coolant
- mixture ratio
fuel
oil
- type
- viscosity
AIRCRAFT OPERATOR
Name
Contact
Address
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Telephone/Fax/E-mail

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BRP-Powertrain
MAINTENANCE MANUAL
Identification
MAINTENANCE FACILITY
Maintenance workshop
Address
Telephone/Fax/E-mail
Certificate
This check is applicable 25 hr. 50 hr.(1 100 hr. 200 hr. 600 hr. 1000 hr.
(circle on)
(1
leaded fuel more than 30% of operation
Next check due at: _______________________________hr.
(TS________) (engine hr.)
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MAINTENANCE MANUAL
5.1) Maintenance Schedule

General note Perform the following maintenance tasks at the intervals shown in the
maintenance check list. See chapter 05-20-00 25 hr. check.
Legend: X = do the task
blank = no task required
NOTES: If the points 1-3 in order to continue with the maintenance

schedule.
If one of the points 1-3 not OK, the engine must be
checked and repaired in accordance with the BRP-Power-
train instructions for continued airworthiness.
Interval Chapter
Points of Inspection Signature
Operating hours Reference
as
100 hr.
indicated
1.) Visual inspection of the engine
General visual inspection of the engine for damage or recommended X 12-20-00
abnormalities. 50 hr. sec. 3)
Check cooling air duct and cooling fins of the cylin-
ders for obstruction, cracks, wear and good condition.
Take note of changes caused by temperature influ-
ence.
Visual inspection of the temperature sensor and the X
oil pressure sensor. Inspect for tight fit and good con-
dition.
Inspect all coolant hoses for damage, including leak- X 12-20-00
age, hardening from heat, porosity, loose connec- sec. 9.1)
tions and secure attachment. Verify routing is free of
kinks and restrictions.
Carry out visual inspection of leakage bore at the X 12-20-00
base of the water pump for signs of leakage. sec. 4)
Inspect the expansion tank for damage and abnor- X 12-20-00
malities. Check coolant level, replenish as necessary. sec. 9.1,9.4)
Inspect radiator cap. 12-10-00
Inspect protection rubber on expansion tank base for sec. 3.1)
correct fit.
Inspect the overflow bottle for damage and abnormal- X 12-20-00
ities. sec. 9.5)
Verify coolant level, replenish as necessary. 12-10-00
Inspect line from expansion tank to overflow bottle for sec. 3.1)
damage, leakage and clear passage.
Inspect venting bore in cap of overflow bottle for clear
passage.
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Interval Chapter
as
100 hr.
indicated
Inspect all oil lines for damage, leakage, hardening X 12-20-00
from heat, porosity, security of connections and at- sec. 4)
tachments. Verify routing is free of kinks and restric-
tions.
Inspect all fuel lines for damage, leakage, hardening X 12-20-00
from heat, porosity, security connections and attach- sec. 4)
ments. Verify routing is free of kinks and restrictions.
In the case of steel fuel lines (912 F, 912 S and/or op-
tional), also check for any cracks and/or scuffing
marks.
Inspect the wiring and its connections for secure fit, X 12-20-00
damage and signs of wear. sec. 13.1)
2.) Magnetic plug
Check the magnetic plug. X 12-20-00
sec. 12)
3.) Compression check
Check the compression by the differential pressure every 200 hr. 12-20-00
method. sec. 5)
Test pressure________hPa (psi)
Pressure drop (% or fraction)

Cyl # 1 2 3 4
bar/psi
4.) Checking the engine suspension

Inspect engine suspension and fasteners for secure X 12-20-00
fit, including damage from heat, deformation, cracks. sec. 3.1)
5.) Checking the air intake system
Inspect suspension and fasteners for secure fit, in- X
cluding damage from heat, deformation, cracks.
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Interval Chapter
as
100 hr.
indicated
6.) Engine external parts
Inspect screws and nuts of all external parts for tight X
fit. Inspect safety wiring, replace as necessary.
7.) Engine cleaning
Engine cleaning X 12-20-00
sec. 1)
8.) Checking the air filter
Checking the air filter. X 12-20-00
sec. 2)
9.) Checking the carburetors
Checking the idle speed. X 12-20-00
sec.10.3.1)
Checking the ventilation of the float chambers. Any 200 hr.
trouble with the float chamber ventilation impairs en-
gine and carburetor function and must therefore be
avoided.
Check that the passage of the ventilation lines is free
and that no kinks can arise.
Check for free movement of the carburetor actuation X 12-20-00
(throttle lever and starting carburetor). sec. 10.6)
Check that the bowden cable allows the full travel of
the throttle lever from stop to stop.
Removal/assembly of the two carburetors for carbu- every 200 hr. Heavy MM
retor inspection. 73-00-00
sec. 3)
Check carburetor synchronization. Mechanical and X 12-20-00
pneumatic synchronization. sec. 10.1)
10.2) 10.3)
Inspect the float chamber assy. for contamination and every 200 hr. 12-20-00
corrosion. See SI-912-021 - latest edition. sec. 10.4)
10.) Inspecting carburetor sockets and drip tray
Inspect the carburetor sockets for damage and ab- every 200 hr. (1 Heavy MM
normalities, checking for cracks, wear and good con- 73-00-00
dition. sec. 3.4.3)
Take note of changes caused by temperature influ-
ence.
(1
See SB-912-030 - latest edition.
11.) Spark plug connectors
d05557.fm
Check that resistance spark plug connectors fit tightly every 200 hr.
on the spark plugs.
Minimum pull-off force is 30 N (7 lb).

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BRP-Powertrain
MAINTENANCE MANUAL
Interval Chapter
as
100 hr.
indicated
12.) Spark plugs
Remove all spark plugs, check the heat range desig- X 12-20-00
nation, clean, check electrode gap and adjust if nec- sec. 13.2)
essary. Replace as required.
Replacing spark plugs. every 200 hr. X(1 12-20-00

sec. 13.2)
(1 use of leaded fuel more than 30% of operation.
13.) Flushing the cooling system
Flushing the cooling system where conventional cool- when replacing 12-20-00
ants are used. the coolant sec. 9.3)
14.) Checking the propeller gear box
Check the friction torque in free rotation on gearboxes X 12-20-00
with overload clutch. sec. 14.1)
Actual friction torque________ Nm (in.lbs)
Gearboxes with overload clutch every 600 hr.(1 05-50-00
(1
use of leaded fuel more than 30% of operation. sec. 2)
Inspect overload clutch. SB-912-033
Checking the propeller gearbox with overload clutch. every 1000 hr.(2 12-20-00
(2
only for engine type 912 S/ULS/ULSFR sec. 14.2)
Checking the propeller gearbox without overload every 600 hr.(3 12-20-00
clutch. sec. 14.2)
(3 only for engine type 912 UL/ULS/ULSFR
15.) Oil change

Drain oil from oil tank. every 50 hr.(1 X 12-20-00
sec. 11.2)
Check the oil tank and clean the oil tank if contaminat- every 200 hr. X(1 12-20-00
ed. 11.5)
(1 use of leaded fuel more than 30% of operation.

Remove old oil filter from engine and install new oil fil- every 50 hr.(1 X 12-20-00
ter. sec. 11.3)
Cut old oil filter without producing any metal chips and every 50 hr.(1 X 12-20-00
inspect filter mat. sec.11.4)
Findings:_________________________________
_______________________________________
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Interval Chapter
as
100 hr.
indicated
Refill oil tank with approx. 3 litres of oil. For oil quality, every 50 hr.(1 X 12-20-00
see Operators Manual and SI-912 -016, latest edi- sec. 11.2)
tion.
(1
use of leaded fuel more than 30% of operation
16.) Oil level check

Verify oil level, replenish as necessary. X 12-10-00
sec. 4.1)
17.) Checking the V-belt tension
On configurations with auxiliary generator, check the X 12-20-00
attachment and the V-belt tension. sec. 6)
18.) Smooth performance of the engine

Inspection of turning of the crankshaft. X 05-50-00
For all engines with crankcase up to S/N 27811 inclu- sec. 3.13)
sive. torque __________Nm
NOTE: At engines with new crankecase
S/N 06.0010 or higher only in-
spect in case of suspected hard
movement.
19.) Engine test run
Observe the safety instructions!
Start the engine and run to operating temperature. X 12-20-00
Limits see Operators Manual 912 series. sec. 8)
Ignition check at _____ rpm engine speed.
Speed drop without ignition circuit:
A (Off)___________rpm
B (Off)___________rpm
A/B (difference)________rpm
Inspect carb heat system.
Hit the preheating and make a note of speed drop.
Speed drop_______rpm.
Preheating “OFF“, engine idle running and make a
note of idle speed running _____rpm.
After engine test run, re-tighten the oil filter by hand
(only at cold engine).
Checks for leaks. 12-20-00
sec. 4)
General note
d05557.fm
All Service Instructions and Service Bulletins are X

complied with.

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BRP-Powertrain
MAINTENANCE MANUAL
Interval Chapter
as
100 hr.
indicated
Return to service
At the identified engine (as per sec. 5), on (Date) _____________________ the________hr.
Check at______hr. (TSN___, TSO___) was carried out according to recommendations of the engine manufac-
turer and was recorded in the Engine Log book.
Location, Date_______________________
Inspector___________________________
Aircraft mechanic_____________________
Certificate No.______________________
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MAINTENANCE MANUAL
Chapter: 05-50-00
UNSCHEDULED MAINTENANCE CHECKS
Introduction In the course of special checks specify if additional
NOTICE
WARNUNG checks for components (e.g. hydraulic governor) is
applicable.
After each special check/repair work, an engine test
run and a leakage check must be carried out.
Observe without fail all the specified instructions.

NOTICE
WARNUNG
Special checks must be carried out immediately in the event of an engine

fault (e.g. abnormal operation as defined in the Operators Manual) which
impairs the airworthiness of the engine.
regarding unscheduled maintenance checks and their associated proce-
dures.
Subject Page
Engine check after propeller strike incidents page 3
Propeller gearbox with integrated overload page 3
clutch
Propeller gearbox without integrated overload page 4
clutch
Checking of the overload clutch page 5
Examination after engine failure page 7
Returning engine to service after submerging page 9
in water
Inspection in extreme climatic conditions page 10
Exceeding of max. admissible engine RPM page 11
Non compliance with the coolant specification page 12
Exceeding of max. cylinder head temperature page 13
Exceeding the max. permissible oil tempera- page 15
ture
Oil pressure below minimum value page 17
Oil specification not respected page 19
Spark plug not in accordance with specification page 21
Non compliance of fuel quality page 21
Smooth performance of the engine page 22
Reporting page 23
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MAINTENANCE MANUAL
NOTES
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September 01/2012
BRP-Powertrain
MAINTENANCE MANUAL
1) Engine check after propeller strike incidents

Definition A propeller strike is:
- Any incident while the engine is stationary or running which makes it
necessary to perform repairs on the propeller.
See SL-912-015, SL-914-012, SL-2ST-009, current edition.
1.1) Propeller gearbox with integrated overload clutch

General note After any propeller strike the following inspections must be performed
before operation can continue.
Step Procedure
1 Inspect the engine for damage. If any damage is detected, inspect, repair
or overhaul the whole engine in accordance with the relevant Manual.
Inspect all systems for correct functioning.
2 Inspect add-on components e.g. propeller governor, vacuum pump, exter-
nal alternator. Observe the manufacturers instruction(s).
3 Observe the directives from the aircraft manufacturer.
4 Remove the fuel pump and gearbox.
5 Remove the roller bearing in crankcase for propeller shaft.
6 The whole gearbox must be inspected, repaired or overhauled in accor-
dance with the BRP-Powertrain instructions for continued airworthiness -
but not limited too
- Carry out detailed inspection of all gearbox components.
- NDT for cracks on gearbox housing, propeller shaft and gear set.
- Inspect drive for governor and vacuum pump (if fitted).
7 Inspect the crankshaft on the power take off side for out-of roundness. See
chapter 72-00-00 section 3.9) of the Heavy Maintenance Manual.
8 Re-install the gearbox.
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BRP-Powertrain
MAINTENANCE MANUAL
1.2) Propeller gearbox without integrated overload clutch

Propeller strike The following inspections must be performed before operation can con-
tinue.
Step Procedure
1 Inspect the engine for damage. If any damage is detected, inspect, repair or
overhaul the whole engine in accordance with the BRP-Powertrain instruc-
tions for continued airworthiness.
Inspect all systems for correct functioning.
2 Inspect add-on components.
3 Observe the directives of the aircraft manufacturer.
4 Remove the fuel pump.
5 Remove the gearbox and roller bearing of the propeller shaft.
6 The whole gearbox must be inspected, repaired or overhauled in accordance
with the BRP-Powertrain instructions for continued airworthiness - but not
limited too
- Carry out detailed inspection of all gearbox components.
- NDT for cracks on gearbox housing, propeller shaft and gear set.
- Inspect drive for governor and vacuum pump (if fitted).
7 Observe the manufactures instructions for the governor, vacuum pump and
propeller.
8 Inspect the crankshaft on the power take off side for out-of-roundness.
Propeller shock load - Inspection of crankshaft distortion on installed crank-
shaft. See chapter 72-00-00 section. 3.9) of the Heavy Maintenance Manual.
9 Re-install the gearbox.
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BRP-Powertrain
MAINTENANCE MANUAL
2) Checking of the overload clutch

General note In the event of lead deposits and/or if slipping is suspected, it will be nec-
essary to check the overload clutch.
NOTES: Slipping of overload clutch is apparent if at engine speed
rise, the propeller speed does not increase at the same
rate.
NOTES: The engine should be run for a short time just prior to the
test, otherwise there is the risk of the clutch „drying out“,
resulting in a higher torque.
Step Procedure
1 Remove the propeller as per manufacturers instruction.
2 Lock the crankshaft. See chap. 12-20-00 section: 7)
3 Danger of damage to the engine suspension!
NOTICE
Depending on the engine installation (e.g. in the case
of extremely lightweight engine suspension), the
gearbox must be removed and the test carried out on
a suitable mounting attachment.
A specially prepared lever (e.g. length 1.5 m (4.92 ft.), see Fig.1) is fitted on
the propeller flange and the breakaway torque measured with a suitable
measuring tool.
NOTE: Because of difficult measurement of the slipping torque
the breakaway torque is measured.
Länge L (m)/
length L in m
Kraft F in N/
force F in N
Fig. 1 08054
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MAINTENANCE MANUAL
Measurement Repeat the measurement several times to get a stable value.

The breakaway torque is calculated on the basis of the force (F) measured
in N and the length of the lever arm (L) used at the normal distance from it
in m (N x m = Nm).
Obtained value Do not exceed 800 Nm (590 ft.lb) otherwise gearbox

NOTICE
WARNUNG damage can occur.
The value determined must be between 600 and 800 Nm (442 and
590 ft.lb.).
If the value is greater or smaller than the limit value, the overload clutch
must be inspected, repaired or overhauled in accordance with the BRP-
Powertrain instructions for continued airworthiness.
Step Procedure
4 Release the crankshaft, see chap. 12-20-00 section: 7).
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MAINTENANCE MANUAL
3) Examination after engine failure

General note In order to find possible causes of the failure, it is important to pass on all
available data. Observations on the aircraft and the engine suspension
can also be of help. It is important to pay particular attention to any of the
following engine phenomena to facilitate troubleshooting.
Engine
Engine runs erratically and misfires
part possible cause
Fuel system fuel supply
vapour locks
contamination
float chamber venting
false air intake due to defective carburetor flange
carburetor icing
Ignition system (shorting cable, malfunction
electronic module, charging coil) grounding defect
Spark plug wrong spark plug connection
Rough running
Rough running engine
part possible cause
Ignition wiring (assignment fault)
Carburetor fuel supply
contamination in float chamber or float needle
valve
float chamber venting
false air intake due to defective carburetor flange
incorrect synchronization of the carburetor
Engine engine temperature too low
too lean carburetor jetting due to conditions pre-
vailing in intake silencer
Engine stoppage Should one of the above mentioned points occur even
NOTICE
WARNUNG for a short time then a detailed check of the engine is
necessary. The fault needs to be located and correct-
ed.
Unintended engine stoppage by seizing

part possible cause
Oil system oil pressure too low or no oil pressure
oil shortage
contamination
d05558.fm
incorrect venting
Oil pump defect

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MAINTENANCE MANUAL
Unintended engine stoppage by seizing

part possible cause
Camshaft bearings/Conrod bearings rather consequential damage wear (low oil
pressure)
The entire assembly must be dismantled, inspected and re-
NOTICE paired.
- The whole engine must be inspected, repaired or overhauled in accor-

dance with the BRP-Powertrain instructions for continued airworthi-
ness.
- Inspect all systems for correct functioning.
- Detailed inspection of affected engine components.
Cylinder head A rise in cylinder head temperature above normal operating limits (see
Operators Manual) is a clear signal for a failure in the cooling system.
Cylinder head temperature too high
part possible cause
Cooling system not enough coolant
bad venting
Return valve is not working malfunction
Radiator contaminated
Radiator cap leaking
Pressure relief valve malfunction
Water pump malfunction
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MAINTENANCE MANUAL
3.1) Returning engine to service after submerging in water

General note The engine must be marked clearly “Engine sub-
NOTICE
WARNUNG merged in water“. Define whether fresh or salt water.
An engine which has been submerged in water must be inspected,
repaired or overhauled in accordance with the BRP-Powertrain instruc-
tions for continued airworthiness.
- Inspect all systems for correct functioning.
- Carry out detailed inspection of affected engine components.
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MAINTENANCE MANUAL
3.2) Inspection in extreme climatic conditions

General note Every 25 hr. checks of air filter, coolant radiator and
NOTICE
WARNUNG oil cooler are necessary.
Flying in deserts or areas with heavily contaminated or dusty air causes
increased wear on all components. For this reason, shorter maintenance
intervals are recommended.
Flying in areas with extreme climatic conditions or in extreme altitudes
requires adjustment of the carburetor jetting and of the cooling system. To
do this, it is necessary to contact the aircraft manufacturer and an autho-
rized ROTAX distributor.
3.3) Returning engine to service after influence by fire

General note An engine after influence by fire must be inspected, repaired or over-
hauled in accordance with the BRP-Powertrain instructions for continued
airworthiness. See therefore affected Maintenance Manual, latest issue.
Inspection - Inspect all systems for correct functioning.

NOTE: Prior to the detailed inspection, all parts should be cleaned and
inspected for weld penetration or melted materials.
If an engine was influenced by fire, first a visual inspection of all parts has
to be done and then a hardeness test of all mechanical parts must be per-
formed (e. g.: crankcase, cylinder, cylinder heads etc.).
In most cases an overhaul is necessary, in this regard send the engine
without delay to an authorized ROTAX overhaul facility for inspection.
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MAINTENANCE MANUAL
3.4) Exceeding of max. admissible engine RPM

General note Any exceeding of the max. admissible engine RPM
NOTICE
WARNUNG must be entered by the pilot into the engine log book
stating duration extent of overspeeding and pertinent
detail.
5800 rpm up to If the limit was exceeded for max. 1 minute and max. 6200 rpm
max. 6200 rpm
Step Procedure
1 No action needed.
5800 rpm up to If the limit was exceeded for more than 1 minute and max. 6200 rpm
max. 6200 rpm
Step Procedure
1 Check that the push-rods are straight.
6200 rpm up to If the limit was exceeded for max. 1 minute and max. 6500 rpm
max. 6500 rpm
Step Procedure
6200 rpm up to If the limit was exceeded for more than 1 minute and max. 6500 rpm
max. 6500 rpm
Step Procedure
1 The whole engine must be inspected, repaired or overhauled in accor-
dance with the BRP-Powertrain instructions for continued airworthiness.
3 Inspect the crankshaft for out-of-roundness. See chapter 72-00-00 section
3.9) of the Heavy Maintenance Manual.
4 Inspect all systems for correct functioning.
5 Detailed inspection of affected engine components.
more than If the speed of 6500 rpm was exceeded

6500 rpm
Step Procedure
1 The whole engine must be inspected, repaired or overhauled in accordance
with the BRP-Powertrain instructions for continued airworthiness.
3 Check differential pressure.
4 Inspect crankshaft with mounted drive gear for runout and distortion. See
chap. 72-00-00 section 3.9) and 3.18) of the Heavy Maintenance Manual.
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5 Check if piston had contact with valve.

6 Check roundness of valves.

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Step Procedure
3.5) Non compliance with the coolant specification

General note
Use only coolant as recommended in the current Op-
NOTICE
WARNUNG erators Manual and SI-912-016 “Selection of
suitable operation fluids“, current issue.
Non compliance with the coolant specification

Step Procedure
1 When a different coolant as the former one (conventional coolant) is used,
then the coolant system has to be flushed.
See chapt. 12-20-00 section: 9.3)
2 Fill in with new coolant
See chapt. 12-10-00 section: 3.1).
3 Re-install the radiator cap.
4 NOTE: Run engine for a minute and replenish as required.
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3.6) Exceeding of max. cylinder head temperature

General note If the maximum cylinder head temperature is exceed-
NOTICE
WARNUNG ed, other limits are also often exceeded, e.g. oil tem-
perature. Please observe the relevant instructions.
NOTES: Any exceeding of the max. admissible cylinder head tem-
perature must be entered by the pilot into the engine log
book, stating duration extent of excess temperature and
pertinent detail.
Graphic Overview and proceed:
Proceed as instructed
in table 2
180 °C
(356 °F) Proceed as
instructed in table 1
Operating limit
(See Operators Manual 912 Series)
0
30 min. Time
Fig. 2 07140
Exceeding Table 1.
up to 180 °C
Exceeding up to 180 °C (356 °F)- short-term
Step Procedure
1 The whole cooling system must be inspected, repaired or overhauled in
accordance with the BRP-Powertrain instructions for continued airworthi-
ness.
2 Inspect all further systems for correct functioning.
Carry out detailed inspection of the affected engine components such as.
- Leakage check on the cooling system.
- Check that the cylinder head attachment is fitted securely. If the cylin-
der head nut is loose, proceed as instructed in sec. “Excess tempera-
ture of over 180 °C (356 °F) and/or for longer than 30 min.“
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Exceeding Table 2.
over 180 °C
Excess temperature of over 180 °C (356 °F) and/or for longer than 30 min.
Step Procedure
ness.
3 Carry out detailed inspection of the affected engine components.
4 Check compression by carrying out a differential pressure check.
5 All cylinder heads and cylinders must be removed and subjected to a de-
tailed check including hardness testing.
See chap. 72-00-00 in the Heavy Maintenance Manual.
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3.7) Exceeding the max. permissible oil temperature

General note If the max. permissible oil temperature is exceeded,
NOTICE
WARNUNG other limits are often exceeded, too, e.g. the cylinder
head temperature. Please observe the relevant in-
structions.
NOTES: Any exceeding of the max. admissible oil temperature
must be entered by the pilot into the engine log book, stat-
ing duration extant of excessive temperature and pertinent
detail.
Graphic Overview and proceed;
Proceed as instructed
160 °C in table 4
(320 °F)
Proceed as
instructed in
table 3
Operating limit
(See Operators Manual 912 Series)
0
15 min. Time
Fig. 3 07140
Exceeding up to Table 3.
max. 160 °C
Excess temperature up to max. 160 °C (320 °F) max. 15 min.
(320 °F)
Step Procedure
1 The whole oil system must be inspected, repaired or overhauled in accor-
2 Inspect oil level in the oil tank.
3 Inspect oil cooler for contamination and check the entire oil circuit for cor-
rect functioning.
4 Check that oil lines are routed correctly and undamaged.
5 Cut oil filter housing and inspect filter mat for foreign matter.
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6 Carry out oil change.


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Exceeding over Table 4.

160 °C (320 °F)
Excess temperature over 160 °C (320 °F) for longer than 15 min.
Step Procedure
1 The whole engine must be inspected, repaired or overhauled in accor-
4 The whole oil system (oil cooler, oil lines) must be inspected.
6 Carry out oil change.
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3.8) Oil pressure below minimum value

General note If the oil pressure falls below the minimum value, other
NOTICE
WARNUNG limits are often exceeded, e.g. the oil temperature.
Please observe the relevant instructions.
NOTES: Any exceeding of the min. admissible oil pressure must be
entered by the pilot into the engine log book, stating dura-
tion extent of excessive pressure and pertinent details.
Graphic Overview and instruction
Oil pressure
Proceed as Operating limit (minimum value)

0,5 bar instructed in (See Operators Manual 912 Series)
(7.25 psi) table 5
Proceed as
instructed in table 6
1 min. Time
Fig. 4 07188
Minimum oil pres- Oil pressure below minimum oil pressure on the ground
sure on the
ground
If noticed on ground, immediately stop the engine and determine the
cause.
- Inspect the complete lubrication system, trace cause and rectify. See
SI-912-005, latest issue.
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Minimum oil If the oil pressure falls below the minimum value up to max. 0,5 bar (7.25
pressure falls psi) and for max. 1 min., the cause must be determined. Table 5.
below 0.5 bar
(7.25 psi) max. 1 Oil pressure below minimum permissible oil pressure up to max. 0.5 bar
min. in flight (7.25 psi) max. 1min. in flight
Step Procedure
1 Inspect all oil lines for restrictions and clear passage.
2 Verify oil quantity.
3 Inspect pressure sensor.
4 Inspect indicating instrument to specifications of the manufacturer, replace
as required.
5 Inspect crankcase pressure (See Installation Manual 912 Series, latest is-
sue.)
6 If no cause for the low oil pressure is found after the above checks, carry
out an oil change.
7 If after the previous checks and oil change the oil pressure is still too low,
repair or overhaul the engine in accordance with the BRP-Powertrain in-
structions for continued airworthiness.
Replace the oil cooler and oil lines. Before the reinstal-
NOTICE
WARNUNG lation of the engine the complete lubrication system
(inclusive oil tank) must be flushed.
Minimum oil Consequent damage can be expected if the oil pressure falls below the
pressure in minimum value more than 0.5 bar (7.25 psi). Table 6.
flight more then
0.5 bar (7.25 psi) Oil pressure below minimum permissible value more than 0.5 bar (7.25 psi) in
flight
Step Procedure
ness.
- Replace the crankshaft.
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3.9) Oil specification not respected

General note NOTES: An entry by the pilot in the engine log book of all pertinent
details is required.
If by error engine was serviced with oil, which does not correspond with
oil specification in the Operators Manual and the engine has been in
operation for less than 5 hours, the following measures must be taken:
less than 5 hr.
Oil specification not respected
Step Procedure
1 Oil change.
2 Remove the lowest positioned banjo screw (1) (banjo bolt, plug screw or
screw socket) and drain the remaining oil from the crankcase. Screw in ban-
jo bolt or plug screw.
Tightening torque see Installation Manual 912 Series.
3 Replace oil filter.
4 Drain oil completely from oil cooler.
5 Drain oil from oil tank.
6 Refill oil tank with oil as specified, refer to Operators Manual.
7 Purge air from oil system. See chap. 12-20-00, section: 11.6).
8 Run engine for approx. 1 hour and replace oil and oil filter once more, as
stated above.
Graphic Position of the plug screw or banjo bolt
pos. 2 1 pos. 1
Druckpropeller Zugpropeller
(pusher config.) (tractor config.)
Part Function
1 banjo bolt
Fig. 5 02712
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longer than 5 hr. If the engine has been operated longer than 5 hours with engine oil not
corresponding with specification in the Operators Manual the following
work is required.
Oil specification not respected
Step Procedure
1 Remove propeller gearbox.
2 The gearbox must be inspected, repaired or overhauled in accordance with
the BRP-Powertrain instructions for continued airworthiness.
4 Oil change.
5 Remove the lowest positioned banjo screw (1) (banjo bolt, plug screw or
screw socket) and drain the remaining oil from the crankcase. Screw in banjo
bolt or plug screw.
Tightening torque see Installation Manual 912 Series.
6 Replace oil filter.
7 Check contact surfaces camshaft/hydraulic tappet.
8 Drain oil completely from oil cooler.
9 Drain oil from oil tank.
10 Refill oil tank with oil as specified, refer to Operators Manual.
11 Purge air from oil system. See chap. 12-20-00, section: 11.6).
12 Run engine for approx. 1 hour and replace oil and oil filter once more, as stat-
ed above.
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3.10) Spark plug not in accordance with specification

General note If by error any of the spark plugs were installed which are not according
to specification of the engine manufacturer and/or not genuine ROTAX
parts, the following verification will be necessary.
Spark plug not in accordance with specification
Step Procedure
1 Mark position of the spark plugs (e.g. cyl. 1 top) and remove all spark plugs.
2 Inspect the spark plugs for damage (formation of melt beads, burn off). At
heavy melt beads or bad burn off, inspect the piston dome and cylinder wall
by borescope. If parts are damaged, the engine must be inspected, repaired
or overhauled in accordance with the BRP-Powertrain instructions for con-
tinued airworthiness.
3 Inspect all systems for correct function.
5 Inspect spark plug thread for damage (especially at bad burn off).
6 Differential pressure check. See chap. 12-20-00 section: 5).
7 Change oil and oil filter.
3.11) Non compliance of fuel quality

General note The use of unsuitable fuel quality has to be entered in the engine log
book.
Non compliance with fuel quality
Step Procedure
1 Visual inspection of engine
2 Empty the fuel system according to the instructions of cell manufacturer
3 Replace fuel filter
4 Flush fuel system
5 Check differential pressure
6 Engine test run
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3.12) Smooth performance of the engine

General note See Fig. 6.
Risk of electric shock!
 WARNING
WARNUNG Ignition “OFF“ and system grounded! Disconnect neg-
ative terminal of aircraft battery.
Inspection Carry out inspection at a temperature from 0° C up to 60° C (140 °F).
Engine runs sluggishly
Step Procedure
1 Remove spark plug connector and remove 1 spark plug from each cylinder.
2 Torque must be determined with a suitable jig.
To do this, determine the maximum occurring torque on the propeller shaft
necessary to move the whole crank drive.
The torque must be max. 150 Nm (110.64 ft.lb).
If the max. permissible torque is exceeded, following inspections are to be
performed:
- Carry out detailed inspection of the affected gearbox components
- Carry out detailed inspection of crank driv
Graphic Measuring torque required to turn crank drive

Länge L (m) /
length L in m
Kraft F in N /
force F in N
NOTES: Always use a propeller guard (edge protection) when per-

forming this inspection.
Fig. 6 05694
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3.13) Reporting
General note According to the regulation of EASA part 21A.3 / FAR 21.3 the manufac-
turer shall evaluate field information and report to the authority. In case of
any relevant occurrences that may involve malfunction of the engine, the
form on the next page should be filled out and sent to the responsible
authorized ROTAX distributor.
NOTES: The form is also available from the official ROTAX AIR-
CRAFT ENGINES Homepage in electronic version.
www.FLYROTAX.com
Register: Document type/Miscellaneous
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NOTES
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Form
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NOTES
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Chapter: 12-00-00
MAINTENANCE OF THE SYSTEMS
Introduction The section “Maintenance of the systems“ is associated with other sec-
tions. It serves only as a supplement to and further explanation of the
maintenance check list (See 05-20-00).
NOTES: For reasons of clarity, only headlines and keywords are
listed in the Maintenance Schedule. Please refer to the
following pages for further explanation if needed.
As far as possible, the content has been arranged accord-
ing to system.
Table of contents This chapter of the Maintenance Manual contains the most common
maintenance procedures.
Subject Chapter
Introduction 12-00-00
Replenishing operating fluids 12-10-00
Scheduled maintenance 12-20-00
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NOTES
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Chapter: 12-10-00
REPLENISHING OPERATING FLUIDS
Introduction The engine should always be in a horizontal position before checking the
fill levels.
ENVIRONMENT NOTE
All operating materials and cleaning products endanger the environment
by improper disposal.
Dispose of the operating materials in an environmentally sound way!
Table of contents This chapter covers the steps required to replenish all operating fluids on
the engine and also provides an overview of the fill capacities.
Subject Page
General note page 3
Fluid capacities page 5
Cooling system page 7
Coolant check/replenish page 7
Lubrication system page 9
Oil level check/replenish page 9
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NOTES
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1) General
Servicing points
on the engine
5 2
1
6
Part Function
1 Expansion tank
2 Radiator cap
3 Oil filter
4 Oil tank
5 Oil tank cover
6 Oil dipstick
Fig. 1 08522
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NOTES
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2) Fluid capacities
General note The operation of the engine may be adversely affected
NOTICE
WARNUNG if non-approved or contaminated fuel, oil or coolant are
used. Any mixing of different manufacturers and types
should be avoided. The use of additives may result in
damage.
System Overview
System Fill capacity Details about the operating fluids
Fuel system Refer to the relevant specifica- Refer to the corresponding chapter
tions provided by the aircraft in the Flight Manual
manufacturer
Cooling system approx. 1.5 l (0.4 US gal.) Refer to the corresponding chapter
in the Installation Manual
Oil system MIN mark corresponds to 2.5 l Refer to the corresponding chapter
(0.66 US gal.) and MAX mark in the Installation Manual
corresponds to 3.0 l (0.8 US
gal.)
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NOTES
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3) Cooling system
3.1) Coolant check/replenish
General note Risk of Burns!
 WARNING
WARNUNG Hot engine parts!
Always allow engine to cool down to ambient temper-
ature before start of any work.
Risk of Burns!
 WARNING
WARNUNG Never open the radiator cap when the cooling system
is hot. For safety’s sake, cover cap with a rag and
open slowly. Sudden opening of the cap could pro-
voke the escape of boiling coolant and result in scald-
ing.
ENVIRONMENT NOTE
Coolant and mixtures of coolant and water have to be treated as
hazardous waste!
Instruction See Fig. 3.

To refill the coolant the following steps are necessary.
Step Procedure
1 Open the radiator cap (1) on the expansion tank (2).
2 Check the coolant level. The coolant level must be filled up to the top (see
Sketch).
3 Inspect coolant with densimeter or glycol tester. Strongly discolored or thick-
ened coolant must be replaced.
4 Use only coolant as recommended in the current Operators
NOTICE Manual.
If necessary, replenish with coolant of same composition.

5 Tighten the radiator cap by hand.
NOTE: The radiator cap must be tightened until the stop lug is
contacted.
Special tools For accomplishment the following special tool is required.

Part number Description
n.a. (1) Densimeter
n.a. (2) Glycol tester
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Graphic Special tool
Fig. 2 05908,05909
Engine test run Engine test run is necessary:

Step Procedure
1 Operate the engine until the temperatures have stabilized for a period of 5 min.
(engine oil temperature between 50 to 70 °C (122 - 160 °F).
2 Switch the engine OFF.
3 Allow the engine to cool down.
4 Check for leaks.
5 Check the coolant level and top up with coolant as required.
Graphic Coolant check/replenish
Part Function
1 Radiator cap
2 Expansion tank
Fig. 3
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4) Lubrication system
4.1) Oil level check/Replenish
General note Risk of Burns!
 WARNING
Always allow engine to cool down to ambient tempera-
ture before start of any work.

 WARNING
WARNUNG Ignition “OFF“ and system grounded! Disconnect neg-
ative terminal of aircraft battery.
ENVIRONMENT NOTE
Be careful that no oil enters the sewerage system or the soil -
Risk of contamination of drinking water!
Collect waste oil and take it to the recycling center.
Preparatory tasks Before checking the oil level, make sure that there is not excess residue
oil in the crankcase.
Instruction See Fig. 4.

For checking and before replenish proceed as follows.
Step Procedure
1 Prior to oil level check, turn the propeller several times by hand in direction
of engine rotation to pump all the oil from the engine to the oil tank.
2 This process is completed when air flows back to the oil tank. This air flow
can be perceived as a murmur (gurgling) when the oil tank cover (1) of the
oil tank is removed.
3 Pull out the oil dipstick (2).
4 The oil level in the oil tank should be between the two marks (max./min.) on
the oil dipstick, but must never fall below the min. mark. See Service Bulletin
SB-912-040, "Introduction of a new oil dipstick", latest issue.
5 For longer flights replenish oil to max. mark to warrant more
NOTICE oil reserve.
During standard engine operation, the oil level should be mid-way between
the max. and min. marks, as at higher oil level (over servicing), oil will escape
via the venting passage see also SI-27-1997, “oil level check“, latest issue.
Difference between “max.“ and “min“. - mark = 0,45 l (0.95 liq.pt)
6 Replenish oil as required.
Only use brand name oil in accordance with the latest Op-
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Step Procedure
7 Check oil level - Marks on the oil dipstick.
8 Fit the oil dipstick and tighten the oil tank cover (1) by hand.
Engine test run Engine test run is necessary:

Step Procedure
1 Operate the engine until the temperatures have stabilized for a period of 5 min
2 Switch the engine OFF.
3 Allow the engine to cool down.
4 Check for leaks.
5 Check the oil level and top up with oil as required.
Graphic Oil level check/Replenish
Part Function
1 Oil tank cover
2 Oil dipstick
Fig. 4 08524
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Chapter: 12-20-00
SCHEDULED MAINTENANCE
Introduction This chapter relates in particular to the maintenance work mentioned in
the Maintenance Schedule for the various engine systems and covers the
work in more detail.
Table of contents This chapter contains information which is required to perform scheduled
servicing on the engine.
Subject Page
Introduction page 1
Engine cleaning page 3
Checking the air filter page 5
Cleaning the air filter page 5
Replacing the air filter page 7
Visual inspection page 9
Checking the engine suspension page 9
Corrosion page 10
Leakage check page 11
Checking the compression page 13
Checking the compression for fault-tracing page 15
Checking the V-belt tension page 17
Locking the crankshaft page 19
Test run of engine page 21
Cooling system page 23
Checking the cool system page 23
Replacing the coolant page 24
Flushing the cooling system page 26
Expansion tank, Radiator cap page 27
Overflow bottle page 29
Accessories page 29
Fuel system page 31
Carburetor synchronization page 31
Mechanical synchronization page 32
Pneumatic synchronization page 34
Idle speed check page 38
Operating range check page 39
Checking of the float chamber page 41
Idle speed adjustment page 43
Checking the carburetor actuation page 44
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Subject Page
Lubrication system page 47
Oil change page 49
Oil filter replacement page 50
Install oil filter page 50
Inspection of the oil filter insert page 52
Cleaning the oil tank page 54
Purging the oil system page 56
Flushing the oil circuit page 56
Inspecting the magnetic plug page 59
Installation of the magnetic plug page 60
Electric system page 61
Check of wiring page 62
Inspection and replacement of spark plugs page 63
Installation of spark plug page 65
Propeller gearbox page 67
Checking the friction torque in free rotation page 67
Checking the propeller gearbox page 68
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1) Engine cleaning
General note
ENVIRONMENT NOTE
When cleaning the engine, the dissolved residues of fuel, oil and other
environment-contaminating agents are rinsed off. Collect the residual liq-
uids and dispose of it in an environmentally sound way
Do not use easily inflammable liquids or caustic
NOTICE
WARNUNG cleaning agents for cleaning the engine.
Cleaning agents Use of a commercially available cold cleaning agent for the engine is rec-
ommended. See chap. 05-00-00 section: 1.5).
Cleaning Never clean an engine with a high pressure cleaner.

NOTICE
WARNUNG This is detrimental to the electrical installations and
shaft seals. Oxidation of the various components and
their failure are the consequence.
Before cleaning, all openings through which cleaning

NOTICE
WARNUNG agents and/or dirty water could enter the engine must
be closed off. Failure to do this may result in engine
damage!
NOTES: Always clean engine in cold state.
If necessary, the engine must be cleaned with due care. Repair leaks as
required before cleaning.
After each clean- After each cleaning procedure, dry all electrical components such as
ing
- Battery
- Ignition unit
- Spark plug connector
- Clamp connections etc.
- Plug connections etc.
by use of compressed air to prevent leakage current.
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2) Checking air filter

General note In the event of dust formation, clean air filter at corre-
NOTICE
WARNUNG spondingly shorter intervals. If filter mat is damaged,
replace air filter.
A dirty filter insert will not only reduce the engine per-
NOTICE
WARNUNG formance but might also promote premature wear of
the engine.
Carry out visual inspection of air filter after prescribed maintenance inter-
val. Clean dirty air filter as described in aircraft manufacturers Mainte-
nance Manual.
2.1) Cleaning the air filter

General note Never use gasoline, steam, caustic liquids, strong de-
NOTICE
WARNUNG tergents, particle cleaning agents or high pressure
cleaners during this step.
Do not dry over naked flame, with compressed air or

NOTICE
WARNUNG with hot air gun.
Cleaning To clean the air filter the following steps are necessary:
See Fig. 1 and Fig. 2.
NOTES: The procedure for cleaning air filter applies to the K&N
style filter supplied by ROTAX (BRP-Powertrain) but may
vary for filters used by aircraft manufacturer.
Step Procedure
1 Lightly tap and brush off surface dirt (A).
2 Spray K&N filter cleaner onto filter surface and leave to soak for approx.
10 min. (B).
3 Rinse air filter with low pressure water from inside to outside and let element
dry naturally (C).
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Graphic Cleaning of the filter
A
B
C
Fig. 1 08525
After cleaning Never use gear oil, diesel or engine oil, as they attract
NOTICE
WARNUNG humidity.
NOTES: Each filter pleat must be sprayed with oil.
After 5 to 10 min. the filter will be soaked with oil, noticeable by the uniform
red coloring.
Fig. 2 08526
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2.2) Replacing the air filter

Each air filter must be secured by clamp attachment
NOTICE
WARNUNG and a wire securing element. See chap. 05-00-00 sec-
tion: 1.6). Filter connection must be free of oil.
Attach new air filter, free of grease, at connection fac-

NOTICE
WARNUNG es, and wire-secure against loss.
Graphic Only use dry type air filters which are specified by the aircraft manufac-
turer and from ROTAX.
2
1
Part Function
1 Air filter
2 Safety wire
3 Carburetor
Fig. 3 08527
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NOTES
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3) Visual inspection
General note General visual inspection of the engine for damage or abnormalities. For
definition and scope of visual inspection (See chap. 05-20-00 section: 3).
Abnormalities Take note of changes caused by temperature influence.

During a visual inspection you should focus on the following points in par-
ticular:
- Exhaust system - Venting hoses (oil tank)
- Airbox - Fuel lines
- Engine suspension frame - Cooler
- Heat shrink sleeve - Coolant hoses
- Oil cooler
3.1) Checking the engine suspension

General note Exactly observe the tightening torques for screws and
NOTICE
WARNUNG nuts. Overtightening or too loose connection could
cause serious engine damage.
Checking the en-

gine suspension
Step Procedure
1 Inspect the engine suspension points on the crankcase for tight fit and dam-
age including cracks.
2 Inspect the surroundings of engine attachment on crankcase and gearbox.
If there is discoloration of the crankcase around the attachment points
(black ring), there may be loose attachments.
3 Inspect engine isolating mounts for heat damage, wear and cracks.
4 Visual inspection of the engine suspension frame for cracks.
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MAINTENANCE MANUAL
3.2) Corrosion
Definition Corrosion is a natural process which attacks and potentially damages met-
als via an electro-chemical reaction. For more detailed information about
different types of corrosion and corresponding methods for dealing with
corrosion refer to the FAA Advisory Circular AC 43.13.
See chapter “AC 43.13-1B Maintenance and Repair“.
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4) Leakage check
General note Leaking connections can lead to engine problems or
NOTICE
WARNUNG engine failure!
Visual inspection of the whole engine for leaks. If leaks are visible, locate
the cause and remedy the fault.
Instruction NOTES: If a leak is suspected, then the following check is possible:

Step Procedure
1 Cleaning the engine.
2 Operate the engine until the temperatures have stabilized for a period of 5
min (engine oil temperature between 50 to 70 °C (122 - 160 °F).
3 Switch off ignition and secure engine against unintentional operation. Se-
cure aircraft against unauthorized operation.
4 For a period of 1 minute after the engine has been stopped, no liquid must
drip down.
Water pump Checking water pump for leaks.

If the leakage bore, located at the base of the ignition housing, is dripping
oil, the oil seal on the water pump shaft may be defective and must be
replaced. In the case of coolant drips at the leakage bore, the coolant
mechanical seal must be replaced (inspect the quality of the coolant).
Fuel lines Inspect fuel lines, their connections and screw fasteners. Look for scuff-
ing marks.
Avoid overstretching the fixing elements. Always
NOTICE
WARNUNG comply with the specified torque!
Detailed visual inspection specially on steel fuel lines in the area of con-
nections (fittings) (2) for leaks and cracks is necessary. See Fig. 4.
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Graphic Connections and fuel lines
2
2
Part Functions
1 Fuel lines (Steel)
2 Connections (Fittings)
Fig. 4 09034
Fuel pump Inspect fuel pump and isolating flange for leaks.For a period of 1 minute
after shut down the engine must not drip oil out of the venting tube. In case
of uncertainty determine the oil amount. An oil leak is when after 20 min
engine run more than 0.5 ml of oil loss is detected.
Coolant hoses Check coolant hoses and connections and fittings for leakage. Examine
the surrounding area to see if there are any leaks!
Oil lines Inspect all oil feed lines from the oil tank to the oil cooler and to the engine.
Also inspect the oil return line from the crankcase to the oil tank. Check
the pressure oil line from the oil pump to the governor flange of the gover-
nor.
Hose clamps, Check all hoses, particularly in the area of the hose clamps and hose con-
kinks nections, for porosity, damage and kinks. If damage is detected, replace
d05561.fm
hose immediately.

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5) Checking the compression

 WARNING
WARNUNG Ignition “OFF“ and system grounded!
Special tools To measure the compression pressure the following special tools and
equipment are necessary.
n.a. Compressed air approx. 6 bar (87 psi).
n.a. 2 pressure gauges.
n.a. Orifice jet*, of 1mm (0.04 in) inner diameter and 3 mm (0.12 in)
length.
* or equivalent e.g. orifice diameter 0.040 in., long 0.0250 in.,
60° degree approach angle according to AC43.13, latest issue.
n.a. Adapter to spark plug thread.
n.a. Connecting hoses.
Instruction Testing is carried out using the differential pressure test procedure.
Step Procedure
2 Started with cylinder head 1 move piston to TDC position.
3 Remove the upper spark plugs. Prevent dirt or other foreigner particles from
penetrating the engine (A).
4 Screw adaptor (1) into the spark plug thread and connect up the two pressure
gauges (2) with the orifice jet (3) between them (B).
5 Now put constant pressure, between 5,5-6 bar (80-87 psi) on the line and take
readings at pressure gauge (C).
6 Repeat this proceeding at all 4 cylinder heads.
Value The maximum permissible pressure drop is 25 %, e.g. from 6 to 4.5 bar
(87 psi to 65 psi) (D).
If the pressure loss is less than 25% then the valve seats and piston rings
are working properly. The spark plug has to be installed according to
chap. 12-20-00 section: 13.2).
If the value is over 25% inspection, repair or overhaul must be carried out
in accordance with the BRP-Powertrain instructions for continued airwor-
d05561.fm
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Graphic Checking the compression.
B
1
3
C
2
Part Function
1 Adaptor
2 Manometer/Test gauges set
3 Orifice jet
4 Compressor
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Fig. 5 08529

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5.1) Compression check for fault-tracing

General note In the course of fault-tracing a compression check can also be per-
formed.
A compression tester is required to check compression. The compres-
sion should be between 9 and 12 bar (130 and 174 psi).
Instruction Compression check for fault-tracing.

Step Procedure
2 Unscrew and remove top spark plugs.
3 Press compression tester (1) over the spark plug hole and use the starter to
turn the engine over with open throttle until maximum pressure is reached.
4 Successively take readings on all four cylinders and compare results.
Measurement Individual readings for the cylinder must not differ by more than 2 bar
(29 psi).
If the value is below 6 bar (87 psi), inspection, repair or overhaul must be
carried out in accordance with the BRP-Powertrain instructions for contin-
ued airworthiness.
Graphic Compression check for fault-tracing
B
1
Part Function
1 Compression tester
Fig. 6 08651
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NOTES
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6) Checking the V-belt tension

General note See also Fig. 8.
In the case of configurations with additional auxiliary generator, inspect
attachment and V-belt tension.
Checking the V- Inspect V-belt tension as per drawing below.

belt tension
Fig. 7 08663
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6.1) Adjust the V-belt tension

Belt tension To adjust the belt tension:
Step Procedure
1 Loosen the hex. screw (1) M10 and the two M8 allen screw (2) and (3).
2 Press the alternator upwards and tighten allen screw (3).
3 Then tighten hex. screw (1) M10 with tightening torque 40 Nm (30 ft.lb) and
allen screw M8 (2) with tightening torque 22 Nm (195 in.lb).
Graphic Checking the V-belt tension
Part Function
1 Hex. screw M10
2, 3 Allen screw M8
Fig. 8 00353 d05561.fm

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7) Locking the crankshaft

General note See Fig. 9 and Fig. 10.
NOTES: The thread bolt for crankshaft locking is part of the stan-
dard tool kit supplied with each engine.
Locking the Risk of severe burns and scalds!

crankshaft  WARNING
ture before start any work.
Special tools For accomplishment the following special tool is required.

part no. 240880 (1) Thread bolt
Part Function
1 Thread bolt
Fig. 9 05910
The following work procedures are to be accomplished:

Step Procedure
1 Remove the plug screw (1) M8x20 and sealing ring from the crankcase half
(cyl. 2/4).
2 Turn crankshaft/propeller shaft until the piston of cyl. no. 1 and no. 2 are in
TDC position and lock crankshaft in this position with the thread bolt (2) part
no. 240880.
NOTES: Turn crankshaft for relief the position indification until the trig-
ger boss (3) is between the both trigger coil (4, 5) at the
position.
d05561.fm
The required recess position of the crankshaft can be addi-

tionally verified by looking through the crankcase recess (6)
with a flash light.

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Step Procedure
3 Screw the thread bolt (2) into the crankcase. While doing so, move the crank-
shaft to and fro slightly with the ring spanner until the locking screw engages
in the recess (6) of the crankshaft, and tighten to 10 Nm (88.48 in.lb).
Loosen the After completion of work/check:
crankshaft
Step Procedure
1 Remove the thread bolt (2) and refit crankshaft plug screw M8x20 (1) along
with a new sealing ring with a torque of 15 Nm (133 in.lb).
Graphic Locking the crankshaft
1
2
3
4
Part Function
1 Plug screw M8x20
2 Thread bolt
3 Trigger boss
4,5 Trigger coils
6 Crankshaft
7 Hex. screw M16x1,5x40
Fig. 10 08530,08531
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8) Test run of engine

General note Danger of life threatening injuries caused by the pro-
 WARNING
WARNUNG peller, rotating and stressed parts of the engine!
Always observe the engine from a safe place while it is
running. Check that the cockpit is occupied by a com-
petent operator.
Preparation Preparation of the engine for test run:

- Ensure that all the operating fluids (engine oil, coolant, fuel) are
replenished to the specified level.
- Make sure that no loose objects (e.g. tools) are left in the engine com-
partment.
- Inspect tight fit of the propeller.
- Anchor the aircraft suitably to the ground and fix wheel chocks. Ensure
that the propeller zone is clear and safe before starting the engine.
Test run Test run as follows:

Step Procedure
1 Establish fuel supply (open fuel cock).
2 Activate choke.
3 Throttle lever to idle position.
4 Master switch “ON“.
5 Ignition for both ignition circuits “ON“.
6 Press starter switch for max. 10 sec. (followed by a cooling period of 2 min.).
7 After engine start, observe oil pressure. Oil pressure has to be built up within
10 sec.
8 Let engine run for approx. 2 min. at 2000 rpm. Then first use the throttle lever
to bring the engine to approx. 2500 rpm and then run through warming up pe-
riod, until the oil temperature reaches 50 °C (122 °F).
9 Check temperatures and oil pressure: At a steady oil temperature above
50 °C (122 °F) and oil pressure above 2 bar (29 psi) engine speed may be in-
creased.
10 Ignition check as per the current Operators Manual.
11 Conduct a short full throttle run and check that the engine reaches the max. full
power speed. Consult the pilot’s operating handbook for maximum speed, as
it depends on the propeller used.
12 After full-load run, conduct a short cooling run to prevent formation of vapour
lock in cylinder heads. This is necessary to prevent steam locks in the cooling
and fuel system after shut-down.
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Step Procedure
13 Shut engine down.
NOTE: On switching off the engine switch off ignition and withdraw the
ignition key.
14 Inspect rotary seal for leakage.
NOTE: Due to the design of the rotary seal, the manufacturer tolerates
a certain amount of leakage. If the leakage is in excess of the
limit rotary seal must be renewed.
Tolerated leakage:
For this check the engine must be operated until all temperatures have stabi-
lized for a period of 5 minutes. At that point shut down engine and ensure the
ignition is switched off and engine secured against unintentional operation.
Coolant must not drip through leakage bore, located at the base of the ignition
housing, for a period of 1 minute after the engine has been stopped.
In case this leakage test can not be passed, the rotary seal must be renewed.
Engine oil and Risk of severe burns and scalds!
coolant  WARNING
is hot. For safety’s sake, cover cap with a rag and open
slowly. Sudden opening of the cap could provoke the
escape of boiling coolant and result in scalding.
Replenish engine oil and coolant as required once engine has cooled
down.
Oil filter If the oil filter has been replaced, re-tighten by hand af-
NOTICE
WARNUNG ter the trial run on a cold engine.
Check of leaks Inspect the engine for oil, fuel or coolant leaks and repair as necessary.
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9) Cooling system
9.1) Checking the cooling system
Overview
Part Function
1 Coolant lines
2 Water pump
3 Expansion tank
4 Radiator cap with gasket
Fig. 11 08532
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General note Risk of severe burns and scalds!

 WARNING
See Fig. 11.
Coolant hoses Carry out visual inspection of all coolant hoses (1) for damage, leaks,
hardening as a result of heat and porosity.
Water pump Inspect all connections on the top and bottom of the cylinder head and on
the water pump (2).
Expansion tank Inspect expansion tank (3) for damage. Inspect protection rubber at the
bottom of the tank for tight fit.
Radiator cap Inspect the gasket of the radiator cap (4) and check the pressure release
valve and return valve for proper operation.
9.2) Replacing the coolant

Risk of severe burns and scalds!

 WARNING
slowly. Sudden opening of the cap could provoke the
escape of boiling coolant and result in scalding.
Use only coolant as recommended in the current Op-

NOTICE
WARNUNG erators Manual and also see SI-912-016.
ENVIRONMENT NOTE
Coolant and mixtures of coolant and water have to be treated as
hazardous waste!
Instruction To replace the coolant the following steps are necessary:
Step Procedure
1 Open the radiator cap on the expansion tank.
d05561.fm
2 Remove the bottom attachment screw (1) (with sealing ring) of water pump (2).

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Step Procedure
3 Drain the engine coolant.
NOTES: If the radiator is located below the engine, also detach the
lowest positioned coolant hose.
4 Fit attachment screw (stainless steel) along with a new sealing ring. Tighten to
10 Nm (90 in.lb).
5 If the coolant is being replaced with a different type, (conventional coolant, wa-
terless coolant) the cooling system must be flushed. See chap. 12-20-00 sec-
tion: 9.3).
6 Refill newly mixed coolant into the expansion tank (highest point of the cooling
system). See chap. 12-10-00 section: 3.1).
7 Fit radiator cap.
8 NOTES: Run the engine briefly and replenish with clean coolant as
required.
Graphic Replacing the coolant
2 1
Part Function
1 Attachment screw (stainless steel)
2 Water pump
Fig. 12 08533
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9.3) Flushing the cooling system

General note Hot steam can cause scalds in the face and on hands!
 WARNING
slowly.
Instruction To flush the coolant the following steps are necessary:

Step Procedure
1 The system is flushed using pure water at a pressure of 2 bar (29 psi).
Where water-free coolant is used, the cooling system must be
NOTICE drained of water correspondingly after flushing. The residual
water must not exceed the max. permissible limit prescribed
by the coolant manufacturer.
NOTES: For the flushing, open the lowest located coolant hose (either
at water pump or radiator).
2 Refill newly mixed coolant into the expansion tank (highest point of the cooling
system). See chap. 12-10-00 section: 3.1).
3 Fit radiator cap.
4 NOTES: Run the engine for a minute and replenish coolant as required.
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9.4) Expansion tank, radiator cap

To equalize pressure in the cooling system, an expansion tank is
required. If the pressure in the system rises above 1.2 bar (17.4 psi) as
the coolant warms up, the pressure relief valve (1) opens and the coolant
can flow into the expansion tank via the line (5). When the coolant cools
down, the return valve (2) opens and the coolant is sucked back.
NOTES: On older engines a radiator cap with opening pressure of
0.9 bar (13.0 psi) can be installed. See SI-912-020 “Run-
ning Modification“, latest issue.
Radiator cap Inspect the rubber seal (3), the pressure spring (4) and the two valves
incorporated in the radiator cap for damage and leaks. If necessary,
replace with a new original radiator cap with 1.2 bar (17.4 psi) (6) open-
ing pressure.
NOTES: The radiator cap must be tightened fully on the expansion
tank.
Expansion tank Inspect sealing surface (7) and tube connection (8) of the expansion tank.
Carry out visual inspection of tank for damage and scuffing marks.
Graphic Checking Expansion tank, radiator cap.
4
7 5
8
3
3 2
Part Function
1 Pressure relief valve
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2 Return valve
3 Rubber seal

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Part Function
4 Pressure spring
5 Connection to overflow bottle
6 Opening pressure of the radiator cap
7 Sealing surface
8 Tube connections
Fig. 13 08534,07620
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9.5) Overflow bottle

Instruction Checking overflow bottle.

Step Procedure
1 Inspect the bottle for damage.
2 Check the venting bore (1) in the screw cap (see Service Bulletin SB-912-039,
“Modification of the overflow bottle“, latest issue).
3 Inspect bracket (2) for the safety wire.
4 Check hose connection (3).
Graphic Overflow bottle
Part Function
1 Venting bore
2 Bracket
3 Hose connection
Fig. 14 08536
9.6) Accessories (including radiator, radiator hoses, hose clamps,

cooling air ducts)
General note Equipment is to be inspected in accordance with the
NOTICE
d05561.fm
WARNUNG Maintenance Manual of the aircraft manufacturer.

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NOTES
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10) Fuel system

10.1) Carburetor synchronization
Idle speed Checking the synchronization at idle speed
See Fig. 15.
For smooth idling, synchronization of the throttle valves is necessary.
When synchronizing, slacken both bowden cables (throttle lever lies
close on the adjustment screw).
Instruction To synchronize when idling the following steps are necessary.

Step Procedure
1 Detach the resonator hose (1) of the compensating tube (2) to separate the
two air intake systems. In this condition, a slight difference in the engine run-
ning should be noticeable.
NOTES: First carry out the mechanical synchronization and then

the pneumatic synchronization (if required).
Graphic Synchronization at idle speed
Part Function
1 Resonator hose
2 Compensating tube
d05561.fm
Fig. 15 05491

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10.2) Mechanical synchronization

Danger of life threatening injuries caused by the pro-
 WARNING
running.
Basic throttle For synchronous basic throttle adjustment proceed as follows.

adjustment
Step Procedure
1 Remove cable fixation (4) on throttle lever (1).
2 Return the throttle lever (1) to its idle stop position (3) by hand. There should
be no resistance during this procedure.
3 Unscrew idle speed adjustment screw (2) until it is free of the stop.
4 Insert a 0.1 mm (0.004 in.) feeler gauge (gap X) between the idle speed adjust-
ment screw (2) and the carburetor idle stop (3), then gently turn the idle screw
clockwise until contact is made with the 0.1 mm (0.004 in.) feeler gauge.
5 Pull out the feeler gauge and then turn each idle speed adjustment screw (2)
1.5 turns clockwise.
6 Gently turn each idle mixture screw (6) (clockwise) until it is fully inserted and
then reopen by 1.5 turns counter clockwise.
7 Check that the throttle valve opens fully automatically.
8 Adjust the two bowden cables for simultaneous opening of the throttle valves.
Carry out the above procedure on both carburetors.
Synchronization You must at this point place the throttle lever in the cockpit to the idle stop
position. It is an advantage at this point to enlist the help of an assistant to
ensure that the throttle lever remains in this position during the next steps
of the synchronization process.
Step Procedure
1 As soon as the throttle lever in the cockpit remains is in the idle stop position,
check the throttle valve lever (1) to the carburetor idle stop position (3).
2 Using the cable fixation (4), secure the bowden cable accordingly.
3 As soon as the two carburetor bowden cables are installed (throttle lever in
cockpit in idle position), you must check that the idle speed adjustment screw
(2) rests fully on the idle stop (3) without pressure.
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Step Procedure
4 An idle speed which is too low can result in gearbox wear,
NOTICE and if the idle speed is too high, the engine is harder to start.
Start the engine and verify the idle speed. If the idle speed is too high or too
low, adjust accordingly with idle speed adjustment screw (2).
5 Check the true running of the engine. If necessary, adjust with the idle mixture
screw (6).
Carry out the above procedure on both carburetors.
Graphic Mechanical synchronization
7
4
1
2
5
8
6
Part Function
1 Throttle valve lever
2 Adjustment screw
3 Idle stop position
4 Cable fixation
5 Return spring
6 Idle mixture screw
7 Idle adjustment
8 Plug screw M3.5x5
Fig. 16 08538
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10.3) Pneumatic synchronization

General note See Fig. 17 to Fig. 19.
Danger of life threatening injuries caused by the pro-
 WARNING
running.
NOTES: Perform a mechanical synchronization before attempting a

pneumatic synchronization.
Special tool The two carburetors are adjusted to equal flow rate at idling with a suitable
flow meter or vacuum gauge(s).
Connection Possible connection methods.

Option 1
Step Procedure
1 Remove the compensating tube (2) from the push on angular tube (4) after re-
moving the two clamp (3).
2 Using the push on angular tube (4) and compensating tube (2) install a flexible
rubber hose (5) leading to the vacuum gauge (1).
Graphic Option 1
1
5
3 5 2 3
4
4
Part Function
1 Vacuum gauge
2 Compensations tube
3 Clamp
4 Angular tube
5 Rubber hose
d05561.fm
Fig. 17 08652

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Option 2
Step Procedure
1 Remove one end of the compensating tube (2) and tube (3) from the push on
angular tube (5) after removing the two tension clamp (4).
2 Using the push on angular tube (5) and compensating tube (2) install a flexible
rubber hose (6) leading to the vacuum gauge (1).
Graphic Option 2
6
2
4
5
3
Part Function
1 Vacuum gauge
2 Compensating tube
3 Tube
4 Clamp
5 Angular tube
6 Rubber hose
Fig. 18 08659
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Option 3
Step Procedure
1 Remove hex. screw (1) M6x6 from intake manifold (2) and connect the vacuum
gauge.
2 Remove the compensation hose (3) with attached resonator hose (4) (connec-
tion between intake manifolds) and plug the fittings in the intake manifolds.
3 After synchronization tightened the screw M6x6 (1) with LOCTITE 221.
Graphic Option 3
1
2
3
1
2
4
Part Function
1 Hex. screw M6x6
2 Intake manifold
3 Compensation tube
4 Resonator hose
Fig. 19 08660
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Option 4
Step Procedure
1 Install the vacuum gauge.
2 Clamp the tube (2) with hose clamping pliers (1). Observe the position! Do not
remove the compensation tube (3).
3 Unscrew the screw (4).
4 Install a hose nipple M6 (5) with sealing ring or O-ring (6).
5 After synchronization remove the hose nipple M6 (5).
6 Secure screw M6x6 (4) with a new gasket (6) and LOCTITE 221.
Graphic Option 4
3
5
4
2
Part Function
1 Clamping pliers
2 Tube
3 Compensation tube
4 Screw
5 Hose nipple
6 Sealing ring
Fig. 20 08661
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10.3.1) Idle speed check

General note Before proceeding, secure the aircraft on the ground using wheel chocks
and ropes.
Risk of life threatening injuries caused by propeller!
 WARNING
WARNUNG Secure the propeller region before test run watch it.
Secure a safe area around propeller during test run.
Start the engine and verify the idle speed. If necessary correct as per
chap. 12-20-00 section: 10.5).
Setting of more than 1/2 turn
If a setting of more than 1/2 turn is required, repeat mechanical synchronization to pre-
vent too high a load on the idle stops. If the idle speed is too high, the maximum the idle
screw can be unscrewed is complete turn.
No satisfactory If an unsatisfactory result is achieved, inspect the idle jets for contamina-
result tion and clean if necessary.
Also check for translucent, jelly-like contamination. In-
NOTICE
WARNUNG spect for free passage.
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10.3.2) Operating range check

General note Once the proper idling speed has been established, it is necessary to
check the operating range above the idle speed.
First establish that the engine is developing full take-off performance or
take-off rpm when selected in the cockpit. Then the setting of the operat-
ing range (idle to full throttle) can be checked or adjusted.
Procedure To control the operating range above idling the following steps are neces-
sary. See Fig. 21.
Step Procedure
1 Start and warm up engine (See Operators Manual). Select full power and check
that both pressure gauges are registering the same readings.
If the same reading is not made on both gauges.
Step Procedure
1 Shut down the engine.
2 Check that carburetor actuation effects full travel and that
starting carburetors (choke) are in the full off position.
3 If necessary, fit/modify the carburetor actuation as required
to achieve full power on both carburetors.
2 Once full power has been established on both carburetors, retard the throttle
and observe the pressure gauge settings. The pressure gauges should show
the same reading for both carburetors.
NOTES: Discrepancies must be compensated for by adjusting the off
idle adjustment (1).
Step Procedure
1 Shut down the engine.
2 Loosening the locknut on the bowden cable and adjusting the
off idle adjustment.
3 Tightening the locknut.
4 Re-testing the engine.
3 Final idle speed adjustment may be required by resetting the idle speed adjust-
ment screws (2).
4 Equal adjustment must be made on both carburetors.
5 Any major adjustments required necessitate replaced verification of all param-
eters mentioned in this procedure.
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Assembly Follow the instructions of the instrument manufacturer.

NOTICE
WARNUNG
- Install compensation tube assy. on engine in reverse sequence of

removal. Any minor differences in balance at idle speed will be compen-
sated for.
- Refit the screw plug M3.5 (3) and hex. screws M6x6 with gasket (pos. 1
Fig. 19).
Graphic Inspect operating range/idle speed
3 4
Part Function
1 Idle adjustment
2 Idle speed adjustment screw
3 Screw plug M3.5x5
4 Idle mixture screw
Fig. 21 08538 d05561.fm

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10.4) Checking of the float chamber

Risk of severe burns or scalds!
 WARNING
Instruction To check of the float chamber the following steps are necessary:
Step Procedure
1 Remove drip tray (1).
2 Open spring clip (2).
3 Remove float chamber (3) with gasket (4) and both float.
4 Remove both float (5) from the float chamber.
5 Inspect the float chamber for contamination and corrosion.
If any contamination on float chamber the find out what

NOTICE
WARNUNG the cause is and take corresponding action to rectify
the problem. Inspect and clean the complete fuel sys-
tem including carburetor.
Step Procedure
6 Assembly at the float chamber should be carried out analogously the disas-
sembly.
7 Adjust with the idle speed adjustment.
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Graphic Float chamber
Part Function
1 Drip tray
2 Spring clip
3 Float chamber
4 Gasket
5 Float
Fig. 22 08653
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10.5) Idle speed adjustment

If satisfactory idle speed adjustment cannot be
NOTICE
WARNUNG achieved, inspection of the idle jet or additional pneu-
matic synchronization will be necessary.
Idle adjustment Always carry out idle speed adjustment when the engine is warm.
- Basic adjustment of the idle speed is first effected using the idle speed
adjustment screw (2) of the throttle valve.
Optimizing en- Necessary only if not taken care of at synchronization.

gine running
Step Procedure
1 Close idle mixture screw (4) by turning clockwise to screw in fully and then
opening again by 1.5 turns counter clockwise.
2 Starting from this basic adjustment, the idle mixture screw (4) is turned until
the highest idle speed is reached.
3 The optimum setting is the middle between the two positions at which an rpm.
drop is noticed.
4 Then readjustment of the idle speed is carried out using the idle speed adjust-
ment screw (2) and if necessary, by slightly turning the idle mixture screw
again.
NOTES: Turning the idle mixture control screw in clockwise direction
results in a leaner mixture and turning counter clockwise in
a richer mixture.
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10.6) Checking the carburetor actuation

Route bowden cables in such a way that carburetor actuation will not be
influenced by any movement of engine or airframe, thus possibly falsifying
idle speed setting and synchronization.
NOTES: Each carburetor is actuated by two bowden cables. At po-
sition (1) connection for throttle valve, and at position (2)
connection for choke actuation.
 WARNING
WARNUNG Adjust bowden cables so that the throttle valve and the
choke actuation of the starting carburetor can be fully
opened and closed. Bowden cables and lever must not
jam!

 WARNING
WARNUNG With carburetor actuation not connected, the throttle
valve is fully open. The initial position of the CD carbu-
retor is full throttle! So never start the engine with the
actuation disconnected.
Procedure To test the carburetor actuation the following steps are necessary:
U
Step Procedure
1 Inspect bowden cables and levers for free movement.
2 Bowden cable must allow full travel of lever from stop to stop.
3 Adjust throttle cables to a clearance of 1mm (0.04 in).
4 Inspect and lubricate linkage on carburetor and carburetor joints with engine
oil.
5 Inspect return springs (3) and inspect engagement holes for wear.
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Graphic Checking the carburetor actuation
~1 mm
3
1
2
Part Function
1 Connection for throttle valve
2 Connection for choke actuation
3 Return springs
Fig. 23 00352
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NOTES
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11) Lubrication
11.1) General
Overview
to oil pump
OU
T
IN
back from engine
1
2 3
Part Function
1 Oil tank
2 Drain screw M12x12
3 Oil cooler
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4 Oil filter
Fig. 24 08238,08650

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General note For detailed information see SI-912-010 “oil change“, latest issue, and
Fig. 24.
 WARNING

 WARNING
WARNUNG Switch off ignition and remove key! Disconnect nega-
tive terminal of aircraft battery.
NOTES: It is advisable to check the oil level prior to an oil change as

it informs about oil consumption.
Observe! Observe the following to prevent possible unintentional

NOTICE
WARNUNG voiding of the oil system and damage to the valve
drive:
- Draining the suction lines, oil cooler and return line is not necessary and
must be avoided, as it results in air entering the oil system. Therefore
see and carry out SI-912-018. See also chap. 12-20-00 section 11.6)
- Replacement of the oil filter and the oil change should be effected
quickly and without interruption to prevent a draining of the oil system
and the hydraulic tappets.
Oil lines, Oil Oil lines and other oil connections are not normally removed.
connections
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11.2) Oil change

Procedure NOTES: Run engine to warm oil before beginning oil change pro-
cedure.
To change the oil the following steps are necessary:
Step Procedure
1 Crank engine by hand to transfer the oil from the crankcase.
2 Remove safety wire and oil drain screw from the oil tank, drain the used oil
and dispose of as per environmental regulations.
3 Replace oil filter at each oil change and inspect the filter insert.
4 Dispose of oil filter according to environmental regulations.
5 Install oil drain screw with new gasket with tightening torque 25 Nm (18 ft.lb)
and safety wire.
Only use brand name oil in accordance with the latest

NOTICE
WARNUNG Operators Manual and SI-912-016, “Selection of suit-
able operating fluids“ latest issue.
The engine must not be cranked when the oil system

NOTICE
WARNUNG is open. When the crankshaft was turned, then the oil
system must be purged.
Compressed air must not be used to blow through the

NOTICE
WARNUNG oil system (or oil lines, oil pump housing, oil bores in
the housing).
ENVIRONMENT NOTE
Be careful that no oil enters the sewerage system or the soil -
Risk of contamination of drinking water!
Collect waste oil and take it to the recycling center.
Step Procedure
6 Install new oil filter.
7 Pour in approx. 3l (0.8 gal (US)) of fresh oil.
8 After carrying out the oil change, the engine should be cranked by hand in the
direction of engine rotation (approx. 20 turns) to completely refill the entire oil
circuit.
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11.3) Oil filter replacement

General note Risk of severe burns and scalds!
 WARNING
To ensure correct functioning of the oil circuit and the

NOTICE
WARNUNG forced flow lubrication, use GENUINE ROTAX-oil filter
only. Only these filters will ensure correct pressure in
the by-pass valve.
At every oil change, unscrew the oil filter and cut open using special tool
taking care not to produce chips.
Special tool To carry out the procedure the following steps are necessary:
part number Description
part no. 877620* (1) Oil filter wrench
part no. 877670* (2) Cutting tool
* or equivalent
877 670
2
1
620
877
Fig. 25 02734
11.3.1) Install/Remove of oil filter

After test run inspect tight fit of oil filter.
NOTICE
WARNUNG
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Procedure To install/remove the oil filter the following steps are necessary:
Step Procedure
1 Remove used oil filter with oil filter wrench.
2 Clean the contact surface (1) of the oil pump housing (2) with a clean cloth.
3 Apply a thin film of engine oil on the gasket (3) of the new oil filter (4).
4 Install the new oil filter on the engine.
5 Screw on oil filter until oil filter gasket is seated solidly.
NOTE: Sign 270 °C-mark on oil pump housing, so that the tightening
of oil filter can be controlled.
6 Tighten oil filter with 3/4 turn (270°).
7 Inspection of used oil filter. See therefore chap. 12-20-00 section 11.4).
Inspect all systems for correct function.
Graphic Install oil filter.
Part Function
1 Contact surface
2 Oil pump housing
3 Gasket
4 Oil filter
Fig. 26 08550
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11.4) Inspection of the filter insert

General note The filter insert must be inspected carefully for metal
NOTICE
WARNUNG chips.
This inspection is important as it allows conclusions to be drawn regarding
the internal condition of the engine and provides information about the
possible cause of any damage.
Procedure To carry out the procedure the following steps are necessary:
Step Procedure
1 Oil filter cut open using special tool taking care not to produce chips.
2 Remove filter insert.
3 Cut top and bottom edges off the mat with a knife.
4 Remove filter mat, fold up and press remaining oil out.
5 Unroll and inspect it for metal chips, foreign matter, contamination and abra-
sion.
6 Pass over matt with a clean magnet and inspect for metal.
Possible for-
eign matter
Steel chips Bronze chips
Aluminium chips Sliver of bearing material
Remains of sealing compound Plastic (thrust washer)
Carbon fiber Sliver of copper
Increased for- If an increased amount of metal particles is found, such as brass- or

eign matter bronze chips or sliver from bearing abrasion, repair or overhaul the engine
in accordance with the BRP-Powertrain instructions for continued airwor-
thiness. If the filter mat is clogged by foreign matter, the lube oil reaches
the bearing points unfiltered via the by-pass valve in the oil filter.
Unclear findings In the case of unclear findings:

Step Procedure
1 Flush the oil circuit.
2 Fit a new oil filter.
3 Engine test run. See chap. 12-20-00 section: 8).
4 Inspect the oil filter once more.
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Contaminated If the oil circuit is contaminated, replace the oil cooler

NOTICE
WARNUNG and flush the oil circuit. See chap. 12-20-00 section:
11.7). Proper judgement requires years of experience
in repair of piston engines.
Graphic Oil filter

to bearings
from oil pump
3
4
2
Part Function
1 Filter housing
2 Filter cover
3 Gasket ring
4 Filter element
5 Filter mat
Fig. 27 08427,00181
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11.5) Cleaning the oil tank

See Fig. 28.
Procedure Procedure to clean the oil tank:
Step Procedure
1 Detach the profile clamp (2) and remove the oil tank cover (3) together with the
O-ring (4) and the oil lines.
2 Remove the inner parts of the oil tank such as the baffle insert (5) and the par-
tition (6).
3 Clean oil tank (8) and inner parts (5, 6) and check for damage.
Incorrect assembly of the oil tank components can

NOTICE
WARNUNG cause engine faults or engine damage.
Step Procedure
4 Fit hex.Double ignition screw (1) M12x12 with a new gasket ring (7). Tighten
to 25 Nm (18.5 ft.lb).
5 Safety wire (9).
6 Reassemble the oil tank by following the same steps in reverse order.
7 Purge the oil system.
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Graphic Cleaning the oil tank
Part Function
1 Hex. screw M12x12
2 Profile clamp
3 Oil tank cover
4 O-ring
5 Baffle insert
6 Partition
7 Gasket ring
8 Oil tank
9 Safety wire
Fig. 28
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11.6) Purging the oil system

General note Purging of the oil system is extremely important for op-
NOTICE
WARNUNG eration and service life of the engine and therefore the
procedure must be followed meticulously. It must be
carried out in accordance with SI-912-018,“Purging
the lubrication system“, latest issue.
Procedure Purging the oil system is necessary:

- before each first start up (e.g. after overhaul)
- after maintenance work during which the lubrication system was
opened and voided.
- when engine was cranked with open oil lines (e.g. during oil change).
- when oil system or oil lines were blown through with compressed air.
11.7) Flushing the oil circuit

General note Risk of electric shock!
 WARNING
Oil lines Dismantle and flush oil lines as per instructions of the aircraft manufac-
turer.
Oil tank Clean the oil tank.
Temporary oil Temporary oil lines (only for flushing) must be fitted so that the oil cooler is
lines not connected. The return line is routed into a separate, clean receptacle
and not back to the oil tank.
NOTES: Otherwise, metal chips could penetrate the radiator or oil
tank during flushing.
Filling Fill the oil tank with approx. 3 l (0.8 gal (US)) of engine oil.
Procedure The following steps have to be carried out after refilling:

The oil level in the tank must not drop below the end of
NOTICE
WARNUNG suction pipe, otherwise air will be sucked in again.
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Step Procedure
1 Turn engine by hand in direction of engine rotation to return the oil from the
oil from the oil tank into the engine and into the collection container. The pro-
cedure is complete when no more contamination can be discovered.
2 Control the oil captured during the rinsing process. The rinsing process is
complete when no more contamination can be discovered.
3 Install cleaned oil lines and oil cooler according to the manufacturers instruc-
tion.
4 Install new oil filter and refill with oil.
Reconnect negative terminal of aircraft battery.

Purging of the oil system, see chap. 12-20-00 section: 11.6).
Equipment Inspect all the equipment in accordance with the Main-

NOTICE
WARNUNG tenance Manual of the aircraft manufacturer.
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NOTES
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12) Inspecting the magnetic plug

NOTES: The magnetic plug is located on the crankcase between
cylinder 2 and gearbox.
This inspection is important because it allows conclusions to be drawn on
the internal condition of the gearbox and engine and reveals information
about possible damage.
Procedure Remove the magnetic plug and inspect it for accumulation of chips.
Steel chips in low Steel chips in low numbers as depicted in Fig. 29 can be tolerated if the
numbers accumulation is below 3 mm (0.125 in).
Steel chips in If there are larger accumulations of metal chips on the magnetic plug, the
larger numbers engine must be repaired or overhauled in accordance with the BRP-Pow-
ertrain instructions for continued airworthiness.
Unclear findings In the case of unclear findings:

Step Procedure
1 Flush the oil circuit.
2 Fit a new oil filter.
3 Engine test run. See chap. 12-20-00 section: 8).
4 Inspect the oil filter once more.
Contamination If the oil circuit is contaminated, replace the oil cooler

NOTICE
WARNUNG and flush the oil circuit.
See chap. 12-20-00 section: 11.7)11.7). Detailed in-
spection of affected engine components.
Trace the cause and remedy.
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Graphic Inspecting the magnetic plug.
magnetic plug
acceptable not acceptable
Fig. 29 08565,08566,08564,08563
12.1) Installation of the magnetic plug

Install The following steps are necessary:
Step Procedure
1 Clean the magnetic plug and oil tank.
2 Install magnetic plug. Tightening torque 25 Nm (18 ft.lb)
3 Install safety wiring.
Inspect all system for correct function. Detailed inspection of affected

engine components.
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13) Electric system

Overview
4 6
5
7
Part Function
1 Spark plug connectors
2 Dual ignition coil
3 Ignition cable
4 Electronic module
5 Plug connectors
6 Grounding cable
7 Protection hose
Fig. 30 08552,08553
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13.1) Check of wiring

General note Risk of electric shock!
 WARNING
WARNUNG Switch off ignition and remove key!

 WARNING
Procedure The following steps have to be carried out:

Step Procedure
1 Inspect all cable connectors and their connections for tight fit, good contact,
corrosion or damage and replace as necessary.
2 Inspect all ground connections for corrosion and damage, replace if necessary.
3 Inspect plug connections between pick-up cable, electronic module, charging
and shorting cables for corrosion or damage and replace as required.
4 Inspect plug connections between electronic module and ignition coils for cor-
rosion or damage and replace if necessary.
5 Verify plug connections of alternator cables with rectifier-regulator and connec-
tions of all cables on rectifier-regulator for good contact, tight fit, corrosion or
damage and replace if necessary.
6 Inspect grounding cables for tight fit, corrosion or damage and replace if nec-
essary.
7 Verify shielding of cable assemblies for corrosion or damage, good ground con-
tact and tight fit, inspect the attachment of the shielding and replace if neces-
sary.
8 Inspect all 8 ignition cables to spark plug connector for corrosion or damage
and tight fit and replace if necessary.
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13.2) Inspection and replacement of spark plugs

Use of incorrect spark plugs can result in ignition prob-
NOTICE
WARNUNG lems and pre-ignition and consequent engine damage.
See chap. 05-50-00 section: 3).
Because of the differing thermal load, particular spark plugs have been
specified for each engine type.
In numerous tests the best possible heat range has been determined to
make sure that the spark plug will burn off deposits but will not overheat.
Renewal intervals NOTES: Operation with leaded fuels (e.g. AVGAS 100LL) can re-
sult in increased wear of the spark plugs. Reduce renewal
intervals accordingly.
Special tool Ensure that the following spark plugs corresponding to engine type are
employed and that the correct spark plug socket is used:
Engine Part no. Designation Size of socket
912 A/F/UL 897255 DCPR 7E 16 mm (0.63 in)
912 S/ULS 297940 DCPR 8E 16 mm (0.63 in)
13.2.1) Remove the spark plugs

Remove Remove the spark plugs and store them according to cylinder and posi-
tion. Always replace both spark plugs of a cylinder and do not inter-
change spark plugs between cylinders.
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13.2.2) Inspection of spark plugs

Heat range Check heat range and adjust electrode gap correspondingly.
Visual check Inspect all spark plugs for mechanical damage.
Electrode gap
Electrode gap
New Wear limit
0,6 - 0,7 mm (0.023 - 0.027 in) 0,9 mm (0.035 in)
NOTES: Inspect the electrode gap also on use of new spark plugs.
The distance can changed by improper handling.
Spark plug face Spark plug face reveals the following about the operating condition of the
engine:
Spark plug face Information
light coloured to brown plug and calibration of the engine are correct
velvet black Indicates the following:
- mixture too rich
- insufficient air intake (clogged air filter)
- engine operating temperature too low
oily, glossy coating Indicates the following:
- damaged valve stem seal
- misfiring
- too much oil in combustion chamber
- worn cylinder and piston rings
white with formation of Indicates the following:
melt beads - mixture too lean
- leaking valves
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13.2.3) Installation of spark plug

Cleaning Eyes and skin irritation!
 WARNING
WARNUNG Rinse off with water in the case of contact with eyes or
skin. May be harmful if swallowed.
Before every installation, the spark plug thread and the spark plug seat at
the cylinder head should be cleaned (e.g. to remove residue of heat con-
duction compound).
Installation Always replace both spark plugs of a cylinder and do

NOTICE
WARNUNG not interchange spark plugs between cylinders.
Heat conduction compound at the ground electrode (1)

NOTICE
WARNUNG or the head area (2) can lead to ignition problems. Ap-
ply heat conduction compound sparingly and do not
apply to the first three threads.
Apply small amount of heat conduction compound to spark plug thread
and tighten spark plug to 20 Nm (177 in.lb) on the cold engine.
Graphic spark plugs

Electrode gap
Part Function
1 Ground electrode
2 Head area
Fig. 31 00086
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NOTES
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14) Propeller gearbox

General note NOTES: The following “free rotation check“ and “friction torque
check“ are necessary only on engines with the overload
clutch as optional extra.
Engine without Engines without the overload clutch (slipper clutch) have no free rotation.
the overload
clutch
For this reason the friction torque method cannot be applied on engines
without overload clutch.
14.1) Checking the friction torque in free rotation

 WARNING
Test procedure The following steps are necessary for the testing procedure:
Step Procedure
1 Fit the crankshaft locking pin. See chap. 12-20-00 section: 7).
2 With the crankshaft locked, the propeller can be turned by hand 15 or 30 de-
grees depending on the profile of the dog gears installed.
This is the maximum amount of movement allowed by the dog gears in the tor-
sional shock absorption unit.
3 Turn the propeller by hand back and forth between ramps, taking into consid-
eration the friction torque. No odd noises or irregular resistance must be no-
ticeable during this moment.
4 Attach a calibrated spring scale to the propeller in distance (L) from the center
of the propeller. Measure the force required to pull the propeller through the 15
or 30 degree range of free rotation.
5 Calculate friction torque (Nm) by multiplying the force (N) obtained on the
spring scale by the distance the scale is attached from the center of the pro-
peller (L).
The friction torque must be between 30 Nm and max. 60 Nm (22 to 44.3 ft.lb).
See calculation example.
If the above mentioned friction torque is not achieved, in-
NOTICE spect, repair or overhaul the gearbox in accordance with
the instructions for continued airworthiness.
6 Remove crankshaft locking pin. See chap. 12-20-00 section: 7).
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Graphic Checking the friction torque.

Länge L (m) /
length L in m
Kraft F in N /
force F in N
Friction torque (Nm) = L (m) (ft) x F (N) (lbf)
Fig. 32 05694
14.2) Checking the propeller gearbox

General note The gearbox must be inspected, repaired or overhauled in accordance
with the BRP-Powertrain instructions for continued airworthiness.
Detailed inspection of the affected gearbox components in accordance
chap. 72-00-00 section: 3.9) in the Heavy Maintenance Manual.
Crack testing of the propeller shaft is not normally planned, but can be car-
ried out if cracks are suspected.
d05561.fm

Edition 3 / Rev. 1
12-20-00
page 68
January 01/2013
AIRCRAFT ENGINES
www.cps-parts.com
800-247-9653

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AIRCRAFT ENGINES

ref. no.: MML-912 | part no.: 899191

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Title page 05-10-00 3 09 01 2012

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chapter page date chapter page date

05-50-00 21 01 01 2013 28 09 01 2012

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The technical content of this document is approved

Note: THE APPROVAL IS GIVEN TO ALL CHAPTERS

0 INTRO all 09 01 2012 DOA*

0 04-00-00 1 09 01 2012 EASA approved

0 05-00-00 all 09 01 2012 DOA*

1 LEP all 01 01 2013 DOA*

60,68 01 01 2013 DOA*

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0 all all 09 01 2012 New Edition.

1 05-10-00 6,7 01 01 2013 Footnote number changed.

56 01 01 2013 Change of text.

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Documentation For more detailed information regarding, maintenance, safety- or flight

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2) Abbreviations and terms used in this Manual

EGT Exhaust Gas Temperature

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part no. Part number

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2.1) Conversion table

Units of length: Units of power:

Units of area: Units of temperature:

Units of volume: Units of velocity:

Units of mass: spec. fuel consumption:

Density: Units of torque:

Units of force: Cable cross-section:

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Identifies an instruction which, if not followed,

Denotes an instruction which, if not followed,

NOTES: Indicates supplementary information which may be

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3.1) Safety notice

Warning It is your responsibility to be completely familiar with the safety instructions

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repair company, ensure that the necessary documentation (log book,

3.3) Maintenance Concept

Maintenance I Chapter 00,05 and 12

Maintenance II separate Manual

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3.4) Technical documentation

Documentation - Installation Manual

Reference This Manual for maintenance is only part of the Technical

BRP-Powertrain, if not stated otherwise.