If you are going to buy the part, you can get it from several different sources such as Lockwood, Leaf, CPS and others rather quickly. It is about $650.00. I know lockwood has them in stock. If you jump through all the hoops to get it replaced under warranty, It may take a while.
Thanks for the suggestions, but I am real nervous about attempting a repair of the threads myself. If I go ahead and try it and am not happy with the result I have then given up any chance of a warrenty claim with Rotax. This is a brand new engine on a brand new Kitfox SS7 and I want things to be right.
You say I will grow old waiting for Rotax replacement parts. How long do you estimate this would take?
Jim
I think you're overthinking this.
1. Take some pictures and send them to Rotax, get an acknowledgement.
2. Buy a M10-1.0 backtap. These things are pretty foolproof. You insert it into the threaded hole, expand it and then unscrew it, chasing the threads as you go. Any metal chips are pulled out of the hole.
3. Install an adapter fitting like this one and go flying.
By the time Rotax sends you the new part you'll decide you don't need it.
I have even a more serious concern about these damaged threads! Since I had to pick out about a half dozen small shards of broken thread, I wonder how many might have gotten into the oil pump and were pumped around the engine to various critical areas during the factory break-in run! I really want to document this in case I have a low hour engine failure due to metallic particles. Unfortunately I didn't take any pictures of the damaged threads and the shards I picked out before I cleaned it up. I don't think that pictures would have showed enough detail anyway.
The damage to the threads would probably not have pushed any pieces of aluminum into the pump. Even if that happened, the oil flow from the oil pump goes directly to the oil filter. So no aluminum would reach the oil galleries in the engine. If you really want to know cut the filter open but I doubt you'll find much.
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