Non-approved modifications or use of ROTAX unapproved engine components

Non-approved modifications or use of ROTAX unapproved engine components
Non-approved modifications or use of ROTAX engines

Information about third party after-market replacement piston kits
The manufacturers of various modifications are suggesting that replacement of the parts in the ROTAX® engines can be easily undertaken by owners or operators. ROTAX® strongly recommends to have the maintenance, especially the removal and replacement of the engine components in ROTAX® engines carried out by ROTAX® authorized representatives, like an authorized Distributor, Service Center, or properly trained and endorsed technician.

No factory testing has been done with engines equipped with these third party replacement kits, modifications and non-genuine ROTAX® components or accessories in ROTAX® engines, therefore the effects on engine performance, reliability and serviceability cannot be predicted. The design, materials and workmanship has not been verified. Defects in design, materials or construction may result in engine damage and / or catastrophic engine failure. Use of third party replacement kits, modifications and non-genuine ROTAX® components or accessories or spare parts (e.g. pistons, cylinder, carburetor, fuel injection system, turbo charger retrofit set,...) may result in some or more of the following:

  • cylinder and piston failure
  • crankshaft or connecting rod failure
  • damage to crankcase
  • lean mixture operating conditions resulting in rough running and / or valve seat- and valve guide burning
  • damage from detonation or pre-ignition
  • hard starting
  • damage to the reduction gear unit
  • negative effect on different systems (fuel system, lubrication system, cooling system) The manufacturers of some third party replacement kits are also supplying instructions for the removal and replacement of components in the ROTAX® engines. These instructions may not be complete and may lead to engine damage during disassembly or re-assembly of the engine. Engine damage may also occur due to incorrect re-assembly of the engine or by the improper reuse of parts such as O-rings and seals.

Example of a “repaired” crankshaft
A supposed exchange crankshaft was purchased and was tested for its quality of repair and overhaul according to the ROTAX® instructions and following was found:

  • The crankshaft has a ROTAX® part no. 888164 and a serial number (S/N) of S/N 11798, but was not marked as overhauled and shows some serious deficiencies:
  • signs of corrosion in the area of the oil seal (pos. 1)
  • crankshaft was beyond the out of round limit
  • torque at twist test was below limit
  • a conrod bearing shows signs of wear (pos. 2)
  • contamination in the oil channels (pos. 3)

Such a crankshaft is not airworthy and should not be installed or any parts reused according to ROTAX® instructions.

Example of non-genuine ROTAX® oil filter
Based on reports from the field a non-genuine ROTAX® oil filter was tested for its quality and suitability according to the ROTAX® instructions, where following was found:
The oil filter infringes on copyright/without permission from ROTAX® a ROTAX ENGINE Type 912/914 label (pos. 1) and has some serious technical deficiencies:

  • no by-pass valve (pos. 2) = in case of contamination this can lead to a completely blocked oil system
  • filter insert (pos. 3): shorter than the genuine = less filter surface and reduced dirt pick-up
  • no genuine ROTAX® part number
  • sharp-edged inner spring (pos. 4) = this can cause wear and cracks in the filter housing
  • no return-valve (pos. 5) = after switching-off the engine self-draining of the oil filter will not be avoided. When the engine is started again it will require a longer time (less film lubrication) until the necessary operating pressure is reached.

Example of a non-genuine ROTAX electric starter
Based on reports from the field a non-genuine ROTAX® electric starter for ROTAX® 912/914 was verified for its quality and suitable according to the ROTAX® instructions, where following was found:
The electric starter uses a ROTAX® 912/914 engine label (pos. 5) without permission from ROTAX® and has some serious technical deficiencies:

  1. no oil seal (pos. 1) in support (pos. 2)
  2. no oil seal (pos. 1) in support (pos. 2)
  3. no standard serial number (pos. 4), which is signed on essential components for traceability at ROTAX

Summary
The use of any third party replacement kits, modifications and non-genuine ROTAX® components or accessories for ROTAX® engines is NOT approved by ROTAX® and is very strongly discouraged. Use of any improper third party replacement kits, improper modifications and non-genuine ROTAX® components or accessories may cause engine damage resulting in catastrophic engine failure. Damages resulting from the use of any improper third part replacements kits, improper modifications and improper non-genuine ROTAX® components or accessories will not be covered by
the ROTAX® limited warranty on the engine.

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