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Rotax Enhanced Annual and Service Class Feb. 24 & 25, 2024

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Rotax 912 Annual & 100 Hour Enhanced Service Class

Expanded Inspection & Service Class

Instructor: Roger Lee in Tucson, AZ

(This is a private class and not a Rotax certified class)


This is a two day class.                                                                                                                                                                                                                                                  

Dates: Feb. 24 & 25, 2024  (0800 hrs. – 1700 hrs)  Cost: $450

Do to the hands on work a maximum class size is 10-12. Pre-registration is needed because classes are usually full.

Phone: 520-349-7056   or  Email: roger@lsamechanic.com

Location: Ryan Airfield in Tucson, AZ

Due to a big demand this class is back. Prepare to learn and have fun doing it!

   This is an improved service level class that will raise and improve the 100 hour and annual inspection understanding. It will guide people to perform at a higher level of education and knowledge base whether you are a private owner or a mechanic. After discussions and feedback with the students that have taken this enhanced Service class with mostly hands on instruction they feel like they are capable of performing at a higher level with inspections, performing simple service work and documenting in the logbook over some other service classes. This class will have a couple hours of classroom each day, but the majority of each day is all hands on work with a functioning Rotax 912ULS and a 912iS engine and targeting the 100 hour / annual inspection and general service work. We will perform an actual annual inspection on a functional aircraft and every student will be supplied with an inspection checklist. We will demonstrate and perform other service functions. While working you will be able to ask real time questions and take notes to help your understanding of the work when you return home. This will empower owners and mechanics to perform better 100 hour and annual inspections, better DOCUMENTATION, and service-based maintenance on the 912 engines. This class will expand on the already successful Rotax Service class by incorporating more hands on time, but more importantly it will expand on better logbook documentation and will focus on a more detailed and  proper inspection process while performing service-level work on the 912 UL, ULS & iS class engine and the 914 engine. This enhanced class will help reduce maintenance induced engine problems and simple time consuming inquiries to the Rotax distributors’ and owners’ maintenance based questions.

  The new Expanded Inspection Service Class and associated demonstrations will include, but not be limited to:


Classroom instruction:  each day is 3-4 hours of classroom with engine part props

(Each student to bring a laptop, IPAD or similar media device)

1.       Registering engines

2.       Finding current manuals on the different internet sites

3.       How to use each manual and its content

4.       Having students demonstrate where to find appropriate documentation for given problems

5.       Service Bulletins and related document recovery from the internet

6.        Understanding Service Bulletin and related material

7.       Understanding what is included in the required 25 hour warranty inspection and its importance

8.       Parts’ time limits and their importance

9.       Check list locations, usage and their importance (Inspection check list)

10.   Logbook entries, their importance and the proper way to log engine information

11.   Researching  and use of proper fluids (Loctite, oils, lubricants and fuels)

12.   Hose change and its challenges.  (The why’s and how’s)

In hangar work and hands on ramp demonstrations:  (approximately 12 hrs)

1.       Following and using the Line Maintenance 100 hr. and Annual check list. (each student will be issued a checklist)

2.       Proper hose inspection and its importance

3.       Proper use of hose clamps, clamping techniques and the tools. Types of clamps and demo each including Oetiker, Band-It, fuel injection clamps and the constant compression spring clamps.

4.       Wiring inspections and what to look for with minor trouble shooting on a few common wiring problems.

5.       Water pump weep hole inspection and what to look for. Information on what to do if coolant is found on the floor from this area.

6.       How to perform an actual oil purge and its proper technique and why this is so important.

7.       Discussion on draining and re-filling the cooling system

8.       Applying heat and vibration shields and what constitutes vulnerable areas.

9.       Remote mounting the oil pressure and or fuel pressure sender      

10.   How to remove pins from plastic wiring connectors (i.e. the ignition modules and regulator/rectifier)

11.   Gearbox friction torque test and how to locate the TDC mark

12.   Perform a differential compression test and discuss its indications

13.   Proper K&N air filter cleaning and oiling

14.   Full class involvement in how to do a mechanical carb sync and a pneumatic sync and how to diagnose carb problems with gauges

15.   Carb inspection and weighing floats

16.   Proper spark plug gapping and thermal paste application.

17.   Oil pressure regulator installation. (plug screw, spring and mushroom)

18.   90 degree coolant elbow inspection for leaks and proper leak repair

19.   Gearbox removal and installation. We will disassemble a gearbox just to allow students to see its interior parts operation (no maintenance, just prep for shipping to a distributor)

20.   Trouble shooting low fuel or oil pressure problems. (How to set up an inexpensive test gauge)

21.   Possible Tanis or Reiff pre-heater application

22.   Fuel pump replacement

23.   Removal and cleaning of the oil tank

24.   Safety wiring the oil pressure regulator plug screw, magnetic plug, air filter and throttle cables when needed

25.   Cutting and inspecting the oil filter (how to wash it for better results)

26.   Header Wrap installation discussion. The do’s and don’ts.

27.   Proper exhaust spring inspection, installation, including safety wire and proper application of high temp silicone

28.   Proper prop pitch setup demonstration. This seems to be a big one for many people. Many owners and A&P’s don’t know how to do this and it’s important for the engine.

29.   Oil and oil filter change and catching an oil sample for a lab analysis. Venting vs Purging

30.   General Trouble shooting (questions & answers)

Rotax class directions 2023.docx Rotax class for 2023.docx

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