Brief Description: Installed new generator mod to the 912is engine
Apparently the wires from the main generator were too small and overheated on someone's plane so Rotax sent me a new generator and wires (which is inside the engine) along with the tools to perform the install. I had to remove the Pipistrel custom motor mount so I could get the air box on the Rotax to lift far enough to clear the bolt that is mounted on the rear cover of the engine. To get at one of the motor mount bolts , I had to remove the outlet fitting on the fuel pressure regulator and used a long hex tool with a ball on the end so it could be at a slight angle. Removed the hoses connecting to the water pump, removed the water pump. Cut off many of the plastic ties holding the wiring to the motor mount. Removed the starter and the crankshaft position sensors. Removed all the bolts on the rear cover and then used the special rear cover removal tool to pop off the rear cover. You must use this tool because the magnets attracting the generator which is attached to this rear cover are very strong. Cleaned off the old gasket material from the back of the engine. Installed new oil passageway o ring. Put engine rebuild grease on all the crank, crank seal and gears. Put new gasket maker silicone on the new back cover. Used rear cover removal tool to lower cover back onto the rear of the engine (working against the strong magnetic pull) while holding air box mount out of the way. Lined up the water pump gear, made sure oil passage o ring was still in place. Replace all the back cover bolts and torqued to manufacturer's spec. Replace water pump with new gasket, re-installed hoses, re-installed starter and crank sensors. Re-installed air box bolt. Re-installed motor mount bolts Used Loctite on all the bolts that were re-installed. I will re-install the outlet fitting on the fuel pressure regulator when I install the engine.
