Rev.5
12-19
ENGINE REPLACEMENT
R
EMOVAL
1. Remove battery ground cable from negative battery terminal.
2. Remove exhaust system. See Exhaust System chapter.
3. Disconnect fuel pump drain tube and hose where attached to the engine.
4. Disconnect oil pressure, EGT, and CHT wires from cylinder heads. Cut tie-wraps
securing wire runs to various engine components as required.
5. Move fuel selector valve to "UP-OFF" position.
6. Place suitable container under gascolator. Remove gascolator bottom plug and
drain fuel from system. NOTE: This is a relatively slow process.
7. Disconnect fuel hose at firewall and gascolator. Some fuel may still be in hoses.
8. Place drain pan beneath engine and drain oil by disconnecting oil hose at pump.
Elevate hose to prevent siphoning oil from tank.
9. Burp engine.
10. Disconnect oil return hose from bottom of engine case.
11. Disconnect oil return hose (where tank is marked "IN") from top of oil tank.
12. Drain cooling system per Rotax Line Maint. Manual.
13. Disconnect throttle and choke cables from carburetor per KAI.
Refer to KAI for remainder of engine removal steps.
I
NSTALLATION
1.
Installation is reverse of removal. Torque fasteners as specified.
2.
Refill coolant system to recommended level.
3.
Refill oil to recommended level.
4. Purge oil system, etc. refer to the Rotax Line Maintenance Manual for this and
other procedures during and after installation. Also refer to applicable KAI sections
throughout the installation.
Torque wrench, many common tools as req'd.
Loctite 221, coolant, engine oil
LSA-RM with Rotax Service certification or A&P
with Rotax Service certification
KAI, Rotax Line and Heavy Maintenance
Manual
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