Installing
the Rotax "C" Gear Box - Gear Drive
1. Clean and degrease the
crankshaft end and mounting holes on the crankcase before
starting.
2. Using the Rotax fixation
tool (876 640) supplied in the Rotax tool kit lock the engine up
by installing the pin into the impulse hole, used to run the
fuel pump. With the pin in place rotate the engine, until it
locks.
3. Install flywheel onto
crankshaft end. Install flat washer onto bolt install bolt..
Torque to 45 FOOT lbs.
4. Install allen screws
with washers into hardee disc. Install Hardee disk onto
crankshaft as shown. Use loctite 242 on bolt threads. Toque to
30 FOOT lbs. While torqueing use a 17 mm wrench to prevent
special flat sided washers from turning.
5. If Hardee disc is banded
remove band..
6. Install back half of
gear box housing onto engine with the 8 bolts provided. Apply
loctite 242 to bolt threads before installing. Torque to 195
INCH lbs.
7. Install #16 shims onto
the pinion shaft.
8. Install anti-seize
compound onto pinion shaft, and install #4 coupling flange.
Torque allen bolt located in the center of the flange to 195
INCH lbs.
9. Install gasket (#21) -
install front gear box housing and prop shaft onto rear housing.
Torque all 6 mm fasteners in an X pattern to 95 INCH lbs.
10. Remove fixation tool
from impulse hole.
11. Fill gear box with 90
weight oil until oil runs out the lower of the two side plugs
(about 4 ounces).
12. Tighten then safety
wire top and bottom plugs.
13. Tighten then safety
wire vent cap and drain plug.
For the Rotax "C" drive
gear box, lubrication oil level is very critical. When
servicing, fill slowly to the lower of the two screw holes on
the side of the case (#39), and then replace the screw and
washer, and safety wire the two oil level screws.
On new gear boxes, change oil after the first 10 hours of
operation and then every 100 hours after that.
Rotax redrive gears must always be replaced together, this is
because of the gears have worn together as a unit and replacing
one would only result in premature wearing of the both gears.
The two large holes on the side of the Rotax "C" drive gear box,
(where you can look in and see the rubber coupler) are for
cooling of the rubber shock mount, inside the drive system and
must be left open.
If there is evidence of
gear oil on the bottom of the gear box where it meets the
crankcase, or in the two holes referred to above this could
indicate a failed seal (#13) inside the gear box. |
