SERVICE LETTER

STANDARDIZATION OF
THE CRANKSHAFT/PISTON PIN AND OF THE GEARBOX
FOR ROTAX® ENGINE TYPE 912/914 (SERIES)
SL-912-002 R2
SL-914-002 R2

Repeating symbols:
Please, pay attention to the following symbols throughout this document emphasizing particular information.
▲ WARNING: Identifies an instruction, which if not followed, may cause serious injury or even death.
■ CAUTION: Denotes an instruction which if not followed, may severely damage the engine or could lead to
suspension of warranty.
◆ NOTE: Information useful for better handling.
A revision bar outside of page margin indicates a change to text or graphic.
1) Planning information
1.1) Engines affected
All versions of the engine type:
Group A
(Introduction of the crankshaft with concial interference fits part no. 888164 with bearing bushing in the
small connecting rod eye)
- 912 A from S/N 4,410.401
- 912 F from S/N 4,412.803
- 912 S from S/N 4,922.501 (from series production)
- 912 UL from S/N 4,404.343
- 912 ULS from S/N 4,425.001 (from series production)
- 912 ULSFR from S/N 4,429.501 (from series production)
- 914 F from S/N 4,420.164
- 914 UL from S/N 4,417.791

(Introduction of the crankshaft part no. 996581 and/or part no. 966583 with bearing bushing in the small
connecting rod eye) only as spare parts part no. 996581 from S/N 99.0023 and/or part no. 966583 from
S/N 8105.

Group B
(Increasing of gear width/overload clutch and/or new dog hub):
- 912 A from S/N 4,410.856
- 912 F from S/N 4,412.973
- 912 S from S/N 4,922.501 (from series production)
- 912 UL from S/N 4,409.671
- 912 ULS from S/N 4,425.001 (from series production)
- 912 ULSFR from S/N 4,429.501 (from series production)
- 914 F from S/N 4,420.164
- 914 UL from S/N 4,417.791
d04708

MAY 28th 2010 Current valid documentation see: SL-912-002 R2

www.rotax-aircraft-engines.com SL-914-002 R2
page 1 of 11
Copyright - BRP-Powertrain GmbH & CO KG. All rights reserved.
 Group C
(Standardization of back lash in the propeller gear box to 30°)
◆ NOTE: UL-engines are only affected if to be used or equipped with an overload clutch.
- 912 A from S/N 4,410.367
- 912 F from S/N 4,412.792
- 912 S from S/N 4,922.503 (from series production)
- 912 UL from S/N 4,403.283
- 912 ULS from S/N 4,425.014
- 912 ULSFR from S/N 4,429.501 (from series production)
- 914 F from S/N 4,420.158
- 914 UL from S/N 4,417.769
- Gearbox from S/N 15.528

Group D
(Gearbox housing part no. 911746 with control processing for gear width)
◆ NOTE: UL-engines are only affected if to be used or equipped with an overload clutch.
- 912 A from S/N 4,410.380
- 912 F from S/N 4,412.796
- 912 S from S/N 4,922.505
- 912 UL from S/N 4,403.413
- 912 ULS from S/N 4,425.290
- 912 ULSFR from S/N 4,429.501 (from series production)
- 914 F from S/N 4,420.173
- 914 UL from S/N 4,417.806
- Gearbox from S/N 15.913
1.2) Concurrent ASB/SB/SI and SL
none
1.3) Reason
In the course of standardization and serial production of 912 S/ULS/ULSFR various standardization have been
also carried out on engine and on gearbox for engine type 912 A/F/UL and 914 F/UL:
- For 912 A/F/S/UL/ULS/ULSFR and 914 F/UL a dog gear of a width increased by 5 mm (0.2 in.) (27 mm (1.06 in.)
wide) was introduced.
- Standardizing to a modified crankshaft.
- Standardizing of the piston pin.
◆ NOTE: Generally the crankshaft with concial interference fits part no. 888164 and/or
part no. 996583 and part no. 996581 with bearing bushing in the small connecting rod eye was
introduced (see Group A).
Furthermore the following standardization for all serial engines of type 912 and 914, configuration with overload
clutch, was carried out:
- Standardizing to back lash from 15° to 30° (see Group C).
- Standardizing of the slipping torque.
- Standardizing of the gearbox housing.
- Clutch hub part no. 958905 with 3 mm (.12 in) longer collar (configuration with overload clutch).
This information is intended to assist the aircraft manufacturer and operator in achieving the proper operating
conditions, correct engine installation and consequently optimum performance and reliability.
1.4) Subject
Standardization of the crankshaft/piston pin and of the gearbox for ROTAX® engine type 912/914 (series).
1.5) Compliance
NONE - For Information Only
1.6) Approval
The technical content is approved under the authority of DOA Nr. EASA.21J.048.

MAY 28th 2010 SL-912-002 R2

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Copyright - BRP-Powertrain GmbH & CO KG. All rights reserved.
 1.7) Manpower
Estimated man-hours:
engine installed in the aircraft - - - manpower time will depend on installation and therefore no estimate
is available from the engine manufacturer.
1.8) Mass data
change of weight - - - none.
moment of inertia - - - unaffected.
1.9) Electrical load data
no change
1.10) Software accomplishment summary
no change
1.11) References
In addition to this technical information refer to current issue of
- Illustrated Parts Catalog (IPC)
◆ NOTE: Due to additional modified the part number in this Service Letter can be out of date.
◆ NOTE: The status of Manuals can be determined by checking the table of amendments of the Manual.
The 1st column of this table is the revision status. Compare this number to that listed on the
ROTAX WebSite: www.rotax-aircraft-engines.com. Updates and current revisions can be
downloaded for free.
1.12) Other publications affected
none
1.13) Interchangeability of parts
- at exchange take care of the following:
■ CAUTION: Proceed according to text and table in this Service Letter because not all parts are compartible
with one another.
2) Material Information
2.1) Material - cost and availability
Price and availability will be supplied on request by ROTAX® Authorized Distributors or their Service Center.
2.2) Company support information
none
2.3) Material requirement per engine
■ CAUTION: For retro-install proceed according to text and table in this Service Letter, because not all parts
are compartible with one another.
2.4) Material requirement per spare part
none
2.5) Rework of parts
none
2.6) Special tooling/lubricant-/adhesives-/sealing compound - Price and availability
Price and availability will be supplied on request by ROTAX® Authorized Distributors or their Service Centers.
■ CAUTION: In using these special tools observe the manufacturers specifications.

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Copyright - BRP-Powertrain GmbH & CO KG. All rights reserved.
3) Accomplishment / Instructions
Accomplishment
All the measures must be taken and confirmed by the following persons or facilities:
- ROTAX® -Airworthiness representative
- ROTAX® -Distributors or their Service Centers
- Persons approved by the respective Aviation Authority
- Persons with type-specific training (applicable only for non-certified engines)
▲ WARNING: Proceed with this work only in a non-smoking area and not close to sparks or open flames. Switch
off ignition and secure engine against unintentional operation. Secure aircraft against unauthorized
operation. Disconnect negative terminal of aircraft battery.
▲ WARNING: Risk of scalds and burns! Allow engine to cool sufficiently and use appropriate safety gear while
performing work.
▲ WARNING: Should removal of a locking device (e.g. lock tabs, self-locking fasteners, etc.) be required when
undergoing disassembly/assembly, always replace with a new one.
◆ NOTE: All work has to be performed in accordance with the relevant Maintenance Manual.
3.1) Increasing of the dog gear width (affected engines "group B"):
On ROTAX® 912 A, 912 F, 912 S, 912 UL, 912 ULS, 912 ULSFR, 914 F, 914 UL a dog gear of a width increased
by 5 mm (0,2 in) was introduced (see fig. 3). This dog gear is part of the gear set 886519.
◆ NOTE: The gear set of increased width is available only for gear reduction ratio 1:2,43.
Increasing of the dog gear width made the following additional modifications necessary:
- Modification of the dog support face (see section 3.1.1)
- Change of the axial design of the crankshaft (see section 3.1.2)
- Additional clearance in the gearbox housing (see section 3.1.3)
- Interim gear set part no. 888680 (see section 3.1.4)
3.1.1) Modification of dog hub and of overload clutch (affected engines "group B"):
The increase in dog gear width made modification of the dog support surface necessary. The dog support
surface is now machined 7° tapered (see fig. 4).
▲ WARNING: A gear set of the increased width must be only paired with the 7° tapered dog hub part
no. 958892 (without overload clutch) and is allowed to be fitted only together with the
overload clutch of new design part no. 996887.
This new dog hub and new dog gear of the overload clutch must never be used in
connection with a gear set of narrow width as the contact surfaces do not match
correctly.
◆ NOTE: The new dog hub and dog gear of the overload clutch and the dog gear of increased
width can be identified by a groove (see fig. 4).

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Copyright - BRP-Powertrain GmbH & CO KG. All rights reserved.
 3.1.2) Standardizing of the crankshafts (affected engines "group A"):
Because of the wider dog gear, it became necessary to change the axial position of the drive gear.
Therefore the crankshaft part no. 888164 is furnished with a longer ending (see fig. 5).
▲ WARNING: If the modified crankshaft part no. 888164 will be installed instead of the previous one
(part no. 996583) take care of the following:
- If the narrow gear set is going to continue to be used, then it will be necessary to
inspect the gear set for traces of wear due to axial staggering between drive gear and
dog gear. If traces of wear are obvious, exchange the gear set for one of increased
width. In this case the overload clutch or dog hub has to be exchanged for use with a
7° dog support face.
- The crankshaft part no. 888164 is only allowed to be installed into the gearbox
housing part no. 911746 (see chapter 3.1.3)
Furthermore the crankshaft (part no. 888164) is furnished with bearing bushing in the small end bearing
(see chapter. 3.3)
■ CAUTION: The crankshaft part no. 996583 with S/N 8105 and/or part no. 996581with S/N 8105,
which only available for spare part service, with bearing bushing in the small end
bearing was introduced. Observe this conditions for using the correct piston pin (see
chapter. 3.3.1).
3.1.3) Gearbox housing assy. part no. 911746 (affected engines, "group D")
The changed axial position of the drive gear and the dog gear of increased width require extra space
in the gearbox housing (see fig. 2).
■ CAUTION: The crankshaft part no. 888164 is allowed to be installed only in the gearbox housing
part no. 911746, where the space between gear set and housing wall will be ensured.
3.1.4) Interim gear set (only for type 914 F and 914 UL)
(see fig. 6)
This gear set is necessary if a gearbox with a narrow gear set has to be converted into a gearbox with
an increased gear set width and for a crankshaft part no. 996583 or older.
◆ NOTE: This gear set is with a drive gear of increased width which compensates for the axial
staggering between crankshaft part no. 996583 and dog gear of increased width.
◆ NOTE: The interim gear set is only available with reduction ratio 2,43.
▲ WARNING: This gear set is allowed to be installed only together with a crankshaft part no. 996583
or of earlier date and in gearbox housing part no. 911746.
3.2) In the course of standardization further modifications of the gearbox were carried out:
Standardization of the backlash on the gear dogs to 30° (affected engines "group C"):
All gearboxes with overload clutch from serial production will be with a backlash of 30°.
◆ NOTE: The backlash of 30° is between dog hub and dog gear.
◆ NOTE: In the future, gearboxes without an overload clutch will have no backlash.

MAY 28th 2010 SL-912-002 R2

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Copyright - BRP-Powertrain GmbH & CO KG. All rights reserved.
 3.3) Standardizing of the piston pin (affected engines „group A“)
With the introduction of the crankshaft part no 888164 (see chapter. 3.1.2) the top (small) connecting rod eye
was equipped with bearing socket, to be improved coupling of material with piston pin.
▲ WARNING: At the crankshaft part no. 888164 must only be used the piston pin part no. 916356. (see fig.
7-10)
3.3.1) Repair of the engine type 914 series:
At repair- and/or overhaul following recommendations must be observe:
- In using of the crankshaft part no. 996583 without conrod bushing (engines previous „group A“),
there must be only 4 nitride piston pin part no. 916420 (black surface) installed. (see fig. 10)
- In using of the crankshaft part no. 996583 with conrod bushing there must be only 4 piston pin part
no. 916356 installed.
- In using of the crankshaft part no. 888164 (engines previous „group A“) there must be only 4 piston
pin part no. 916356 installed.
3.3.2) Repair/Overhaul of the engine type 912 series:
All these engines the piston pin part no. 916356 can be install without considering the serial number.
■ CAUTION: For reason of weight limits there must be only 4 same piston pin installed in one engine.
To prevent any mix-up, see the illustration fig. 7 to 10.
3.4) Summary
▲ WARNING: Non-compliance with these instructions could result in engine damage, personal injury or
death!

Approval of translation to best knowledge and judgement - in any case the original text in German language and
the metric units (SI-system) are authoritative.

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Copyright - BRP-Powertrain GmbH & CO KG. All rights reserved.
 3.5) Overview
The following table shows which components are together compatible:
Conduct test run including ignition check and leakage test.

Kombinationsmöglichkeit / combination

Überlastkupplung (TNr. 996883), rechtwinkelige Klauennabe

overload clutch (part no. 996883), rectangular dog hub

Zahnradsatz 1:2,43 (Interim, Klauenrad breit, 27 mm) (5)

Zahnradsatz 1:2,27 (Klauenrad schmal, 22 mm) (5)

Zahnradsatz 1:2,43 (Klauenrad schmal, 22 mm) (5)

gear set 1:2,43 (interim, dog gear wide, 27 mm) (5)

Klauennabe rechtwinkelig (TNr, 958920)
dog hub rectangular (part no. 958920)

overload clutch 7° (part no. 996887)

Überlastkupplung 7° (TNr. 996887)

gear cover up to S/N 15.912 (part no. 911748)

gear cover from S/N 15.913 (part no. 911746)

Getriebedeckel bis S/N 15.912 (TNr. 911748)
Klauennabe 7° (TNr. 958892)

Getriebedeckel ab S/N 15.913 (TNr. 911746)

gear set 1:2,27 (dog gear narrow, 22mm) (5)

gear set 1:2,43 (dog gear narrow, 22mm) (5)

dog hub 7° (part no. 958892)

Zahnradsatz 1:2,43 (Klauenrad breit, 27mm)

gear set 1:2,43 (dog gear wide, 27mm)
Gemeinsame Verwendbarkeit der Verschiedenen
Zahnradsätze, Klauennaben, Rutschkupplungen,

Kolbenbolzen TNr. 916356 (3) (9)

piston pin part no. 916356 (3) (9)
crankshaft new, part no. 888164
Getriebedeckel und Kurbelwellen: common use of the different

crankshaft part no. 996583 (5)

Kolbenbolzen TNr. 916355 (7)

Kolbenbolzen TNr. 916420 (8)

gear sets, dog hubs, slipper clutches, gear box housings and

piston pin part no.916355 (7)

piston pin part no.916420 (8)

Kurbelwelle TNr. 996583 (5)
crankshafts:

Kurbelwelle TNr. 888164

Überlastkupplung (TNr. 966883), rechtwinkelige
Klauennabe yes yes no no
overload clutch (part no. 966883), rectangular dog hub
Klauennabe rechtwinkelig (TNr. 958920)
yes yes no no
dog hub rectangular (part no. 958920)
Überlastkupplung 7° (TNr. 996887)
no no yes yes
overload clutch 7° (part no. 996887)
Klauennabe 7° (TNr. 958892)
no no yes yes
dog hub 7° (part no. 958892)
Zahnradsatz 1:2,27 (Klauenrad schmal, 22 mm) (5) yes
yes yes no no yes yes yes
gear set 1:2,27 (dog gear narrow, 22mm) (5) (1)
Zahnradsatz 1:2,43 (Klauenrad schmal, 22 mm) (5) yes yes
yes yes no no yes yes
gear set 1:2,43 (dog gear narrow, 22mm) (5) (1) (2)
Zahnradsatz 1:2,43 (Klauenrad breit, 27mm) yes yes
no no yes yes no no
gear set 1:2,43 (dog gear wide, 27mm) (3) (2)
Zahnradsatz 1:2,43 (Interim, Klauenrad breit, 27 mm) (5) yes yes
no no yes yes no no
gear set 1:2,43 (interim, dog gear wide, 27 mm) (5) (1) (2)
Getriebegehäuse bis S/N 15.912 (TNr. 911748) yes yes yes
no no no
gearbox housing up to S/N 15.912 (part no. 911748) (1) (1) (4)
Ausgangsbasis / starting base

Getriebegehäuse ab S/N 15.913 (TNr. 911746) yes yes

yes yes yes yes
gearbox housing from S/N 15.913 (part no. 911746) (3) (1)
Kurbelwelle TNr. 996583 (5) yes yes yes no
yes yes no yes yes
crankshaft part no. 996583 (5) (2) (4) (11) (10)
Kurbelwelle TNr. 888164 yes yes
yes no no yes no no no no yes
crankshaft new, part no. 888164 (2) (2)
Kolbenbolzen TNr. 916355 (7)
yes yes
piston pin, part no. 916355 (7)
Kolbenbolzen TNr. 916420 (8) yes
no
piston pin, part no. 916420 (8) (11)
Kolbenbolzen TNr. 916356 (3) (9) yes
yes
piston pin, part no. 916356 (3) (9) (10)
1) nur mit Kurbelwelle TNr. 996583 oder älter 7) nur bei Motortype 912 A/ F (Motoren vor Gruppe A) und 912 UL
1) only with crankshaft part no. 996583 or older 7) only at engien type 912 A/ F (engines before group A) and 912 UL

2) nur mit Getriebegehäuse ab S/N 15.913 (TNr. 911746) 8) nur bei Motortype 914 F/ UL (Motoren vor Gruppe A)
2) only with gearbox housing from S/N 15.913 (part no. 911746) 8) only at engien type 914 F/ UL (engines before group A)

3) nur mit Kurbelwelle TNr. 888164 9) Der Kolbenbolzen TNr. 916356 kann für alle Motoren der Type 912 UL/ A/ F/ S/ ULS/ ULSFR verwendet werden.
3) only with crankshaft partno. 888164 9) The piston pin part. no. 916356 can be used at engine type 912UL/ A/ F/ S/ ULS/ ULSFR.

4) nur mit schmalen Zahnradsätzen 10) zulässig, sofern Kurbelwelle mit Buchse in kleinem Pleuelauge versehen ist
4) only with narrow gear sets 10) permissible if crankshaft has bushing in small end bearing

5) nicht erlaubt bei Motoren Gruppe B 11) nicht zulässig, sofern Kurbelwelle mit Buchse in kleinem Pleuelauge versehen ist
5) not allowed on engines group B 11) not permissible if crankshaft has bushing in small end bearing

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4) Appendix
the following drawings should convey additional information:

31,5mm

XXX Seriennummer
serial number

134 mm dia.
ø 134 mm
Bild / Fig. 1
02879

65 mm dia.
ø 65mm
30,5mm

Bild / Fig. 2
03225
22
mm
(0.
87
in.
)

27
mm
(1.
06
in.
)

schmal /
narrow

Bild / Fig. 3
breit / wide
03047

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 für breiten Zahnradsatz für schmalen Zahnradsatz
for wide gear set for narrow gear set

90°

Z
Detail Z
Erkennungsrille 03049
Bild / Fig. 4
identification groove

Bild / Fig. 5 07301

Absatz
step

ANTRIEBSRAD FÜR
ZAHNRADSATZ
INTERIM

DRIVE GEAR FOR

INTERIM GEAR SET

Bild / Fig. 6 03254

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 Type 912 Series
Kurbelwelle TNr. 888164 ab Serie
crankshaft part no. 888164 with start of
serial production
Kurbelwelle TNr. 996583 bis S/N 8104 und/and
crankshaft part no. 996583 to S/N 8104 Kurbelwelle TNr. 996583 ab S/N 8105
crankshaft part no. 996583 from S/N 8105

Bild / Fig. 7

04068 04069
Lagerbuchse
bushing

Kolbenbolzen
piston pin

04066
04065
Bild / Fig. 8
TNr. / part no. 916355 TNr./ part no. 916356
Gewicht / weight ~ 75g Gewicht/ weight ~ 85g
➠

ersetzt durch/ replaced by

04066

TNr. / part no. 916356

Gewicht / weight ~ 85g

■ CAUTION: Observe the combination options of the piston pin in accordance chapter 3.3.

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 Type 914 Series

Kurbelwelle TNr. 888164

crankshaft part no. 888164
und/and
Kurbelwelle TNr. 996583 bis S/N 8104 Kurbelwelle TNr. 996583 ab S/N 8105
crankshaft part no. 996583 to S/N 8104 crankshaft part no. 996583 from S/N 8105

Bild / Fig. 9

04068 04069

Lagerbuchse
bushing

Kolbenbolzen
piston pin

nitrierte Oberfläche
nitrated surface

Bild / Fig. 10

04067 04066

TNr./ part no. 916420 TNr./ part no. 916356

Gewicht/ weight ~ 87g Gewicht/ weight ~ 85g

◆ NOTE: The illustrations in this document show the typical construction. They may not represent full detail
or the exact shape of the parts which have the same or similar function.
Exploded views are no technical drawings and are for reference only. For specific detail, refer to
the current documents of the respective engine type.

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Copyright - BRP-Powertrain GmbH & CO KG. All rights reserved.