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rotax 4-stroke - overhaul
912UL, 912A, 912F, 912ULS, 912S, 914UL and 914F Engines
All information provided here is correct at the time of publishing to the best of our knowledge, but Rotax recommendations may change at any time without our knowledge. It is the engine owners responsibility to ensure that the engine is fit for flight at all times. The information is provided here free of charge and with no obligation from us to the consumer. To ensure that you have the correct and most up to date information, you should refer to the current Installation, Operators and Maintenance manuals for your engine. The information provided here may not be valid for aircraft outside the UK. Click here for ConAir SportsTerms& Conditions, including website usage policy.
It is sometime possible to upgrade engines to a higher TBO Refer to the relevant service bulletins for engine serial numbers and work required. Sometimes this is a fairly simple procedure, but often the cost of upgrade can be significant and depends on parts required as specified in the service bulletins.
Service bulletins can be downloaded from the Documentation section at www.rotax-aircraft-engines.com
Overhaul is a specific term required after a specific period of operation (or lifetime). Overhaul includes the following:
100% replacement parts - parts which must be replaced in their entirety at every overhaul regardless of their operation period. These parts include a number of significant parts including the crankshaft.
On Condition parts - all other parts, replacement of which will be determined either on the basis or hours of operation, or by measurement of actual dimensions.
Once overhauled, you then have another TBO period before overhaul is required again, but your engine HAS NOT been “Zero Houred”.
Due to the 100% replacement parts required at overhaul, the cost of overhaul is usually around 75% the price of a newengine, click here for pricing info. Also bear in mind that expensive electrical items, such as SMD modules are not 100% replacement items, and these parts will be original even on an overhauled engine. Click here for example prices.
Time before overhaul depends on engine serial number and is given in the Line Maintenance Manual for the engine type.
The main items to be replaced at overhaul to include, but not limited to (some items are only required on certain engine types and some additional items will be required):
- Crankshaft - Suspension frame - Carb overhaul
- Bearing shells - Vaccum pump - Pressure regulator
- Exhaust valves - All ball and roller bearings - Fuel pumps
- Valve spring retainers - Hoses - Govenor
- Pistons - Oil tank cap - Ring halves
- Piston rings - Radiator cap - Spark plugs
- Sprag clutch - External alternator - Plug caps
- Turbo charger
Buying a used overhauled engine, see section of what to look out for when buying a used engine, click here.