Hello all
Jeff you are correct, the factory has stated that it is for approved overhaul facilities that have the correct tooling and approvals from the distributor of that country. The manual is only released on that condition. The Rotax distributor will not sell the overhaul kit to independent iRMT. The good part is other than splitting the case you can do almost anything else as you see in the heavy maintenance manual.
An authorised overhaul kit comes with crankshaft assembly complete. The camshaft with lifters, all gaskets and Orings and seals. The parts to overhaul the starter, water pump and electrical parts that require change. Piston rings, exhaust valves, all the bearings for gearbox and wear parts with a host of other small bits. The overhaul appendix has to be filled in complete and a test run before overhaul and after with calibrated prop, airbox and hot test at the end to confirm operation. All electrical parts have to be bench tested to confirm function such as advance curve or step in the case of the SMD modules. Electrical load of the charging system also must be tested. (stator function and output under load) Valve seat cutting to factory spec and any valve guide check, alignment or replacement as required.
For the most part most people who claim to do 3rd party overhauls actually only do repairs of the existing parts and do not actually follow the procedures in my opinion.
Cheers
