Rotax 912 i series Service Manual

BRP-Rotax
MAINTENANCE MANUAL LINE
Chapter: 12–20–00
SCHEDULED MAINTENANCE
TOPICS IN THIS CHAPTER
Engine cleaning.......................................................................................................................................3
Visual inspection.....................................................................................................................................4
Checking the engine suspension ............................................................................................................4
Corrosion..............................................................................................................................................4
Leakage check.........................................................................................................................................5
Differential pressure check......................................................................................................................7
Compression check for fault-tracing ........................................................................................................9
Engine management ECU...................................................................................................................... 11
Checking ECU ....................................................................................................................................12
Read out the ECU data memory ...........................................................................................................12
Locking/Loosen of the crankshaft .........................................................................................................13
Test run of engine..................................................................................................................................15
Checking the V-belt tension...................................................................................................................17
Belt tension adjustment........................................................................................................................18
Air intake system...................................................................................................................................19
Checking air intake system...................................................................................................................20
Cleaning the dry air filter ......................................................................................................................20
Replacing the dry air filter.....................................................................................................................22
Cooling system .....................................................................................................................................23
Checking the cooling system ................................................................................................................24
Replacing the coolant ..........................................................................................................................24
Flushing the cooling system .................................................................................................................26
Expansion tank, radiator cap ................................................................................................................27
Overflow bottle ....................................................................................................................................28
Accessories (including radiator, radiator hoses, hose clamps, cooling air
ducts) .................................................................................................................................................28
Fuel system ...........................................................................................................................................29
Leak tests ...........................................................................................................................................30
Checking the fuel lines .........................................................................................................................30
Checking the fuel pressure regulator.....................................................................................................30
Fuel pumps.........................................................................................................................................31
Check valves ......................................................................................................................................31
Fuel injectors ......................................................................................................................................31
Fuel rail ..............................................................................................................................................31
Lubrication ............................................................................................................................................32
Oil change ..........................................................................................................................................34
Oil filter replacement............................................................................................................................35
Inspecting of the oil filter components....................................................................................................37
Installing new oil filter...........................................................................................................................39
Cleaning the oil tank ............................................................................................................................40
Purging the oil system..........................................................................................................................42
Effectivity: 912 i Series
Edition 2/Rev. 0
12–20–00
Page 1
September 01/2018

Rotax 912 i series Specifications

General

Number of Cylinders	4
Max Power	100 hp (73.5 kW)
Max Power Output RPM	5800 rpm
Ignition System	Dual electronic ignition
Oil System	Dry sump, forced lubrication with separate oil tank
Reduction Gear Ratio	2.43:1
TBO	2000 hours
Engine Type	4-stroke, horizontally opposed
Displacement	1352 cm³
Bore x Stroke	84 mm x 61 mm
Max Torque	128 Nm
Fuel Type	Avgas 100LL or unleaded automotive gasoline
Fuel System	Electronic fuel injection
Cooling System	Liquid/air-cooled