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ROTAX 912 5YR RUBBER REPL KIT

in General Tech Discussion 12 years ago

  • Re: ROTAX 912 5YR RUBBER REPL KIT

    by » 12 years ago

    Thanks for your considered and nuanced reply, Eric.

    Pardon my ignorance, but I`m a bit confused about what all is involved in full rubber replacement:

    From Roger`s replies it sounded like what he was most concerned about was rubber fuel, oil, and water lines.
    I was under the impression (strictly by imagining) that what Rotax was talking about would include much more -- every big or tiny gasket or seal anywhere. Did I get that right?

    Or if it`s ``just hoses`` and turning into a $3500 job, I must be badly misunderstanding the complexity and number of hoses as at a casual glance if it`s external hoses only from my inexperienced position it`s hard to see how it could be $1000 worth of hoses and 30 hours of work.
    Mind you, I`m _not_ doubting you`re reporting accurately.

    What am I missing? That the complete rubber replacement is a lot _more_ than the hoses?
    That there are more hoses than I see from scanning the engine?
    That Rotax charges about 10 times for each hose than a comparable looking hose at NAPA would cost?
    That there`s much more work to getting them off and on than someone who`s not an Rotax mechanic and has never tried it thinks?
    Or?

    Al
    P.S. Given the hours on our 912UL and more so the age,
    if we decide it`s really prudent to do $3500 worth of rubber replacement we might consider biting the bullet doing a complete rebuild.
    Am I right in assuming any reputable rebuild would INCLUDE full rubber replacement?
      
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  • Re: ROTAX 912 5YR RUBBER REPL KIT

    by » 12 years ago

    Hi Al,

    It is just the rubber fuel, oil and coolant hoses. It is the carb diaphragm and the carb rubber intake socket. Rotax did just recently add the fuel pump to their list. It isn't rubber spark plug wires or other rubber parts. If you have not done a carb rebuild in many years then I would add that to my list. If your engine is that old and never had the carbs done you probably have the old red tip float needle. Plus I guarantee the carb "O" rings are shot. They will be dry, cracked, flat and brittle. If the floats are that old it would be a good idea to replace them too. I'm going on the assumption that your plane is 10 years old?

    How can parts add up to $900? That's easy. These are approximates off an old invoice and there may be some newer pricing. I'm not going to list each part by number or the hose footage. This was for a Flight Design CT.
    Rubber carb flange x 2 = $220
    "O" rings x 2 = $13
    1" or 25MM radiator hose $60
    1/4" gates fuel hose $60
    5/16" fuel hose $85
    13mm oil hose $65
    66mm carb cross over tube hose x 2 = $14
    90 degree coolant hose $55
    17mm coolant hose $120
    "O" ring x 2 = $45
    "O" rings for the valve covers $65
    Crush washers $23
    2 carb diaphragms $182
    If you have the red Teflon hose for the carb feed then that's another #388 ( your engine does not have this hose)

    I believe that brings the approximate price to $1007.

    Yours will differ some depending on over all hose lengths. There could be a part or two you could dispense with and maybe a part or two you would add.

    This doesn't cover the rubber engine mounts that get hard and crack. Even if they don't crack as they get old they get hard and then loose there elasticity and the engine starts to vibrate more. All always change rubber engine mounts if you are into this process this far. That price could be any where from $60 to $250.

    Roger Lee
    LSRM-A & Rotax Instructor & Rotax IRC
    Tucson, AZ Ryan Airfield (KRYN)
    520-349-7056 Cell

    Thank you said by: Eric Gray
      
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  • Re: ROTAX 912 5YR RUBBER REPL KIT

    by » 12 years ago

    Here are a few current pictures of hose that came off at 5 years. Some are cracked some have reduced radius. It didn't have to work at finding any of these. I see it all the time. If you have never done a hose change then what would someone have to compare to if they say it doesn't need to be done. If you have done 35-40 rubber replacements then you get a better overall picture and see lots and lots of hose and what really goes on.







    Crackedcoolanthose.jpg (You do not have access to download this file.)
    Leftsidecoolanttubewithcrackedhosetotheright.jpg (You do not have access to download this file.)
    Restrictioninhosefromsafetywire.jpg (You do not have access to download this file.)

    Roger Lee
    LSRM-A & Rotax Instructor & Rotax IRC
    Tucson, AZ Ryan Airfield (KRYN)
    520-349-7056 Cell

    Thank you said by: Eric Gray
      
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  • Re: ROTAX 912 5YR RUBBER REPL KIT

    by » 12 years ago

    This short piece of fuel injection hose shows what happens when someone forces FI hose over a barbed fitting. It causes mechanical damage and debris floats downstream.


    fuelinjhose003.jpg (You do not have access to download this file.)

    Roger Lee
    LSRM-A & Rotax Instructor & Rotax IRC
    Tucson, AZ Ryan Airfield (KRYN)
    520-349-7056 Cell

    Thank you said by: Eric Gray
      
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  • Re: ROTAX 912 5YR RUBBER REPL KIT

    by » 12 years ago

    Here are a few pictures from people that have not taken the time to pick the right hose and use proper sterile install techniques









    .
    carbbowl1.jpg (You do not have access to download this file.)
    carbbowl.jpg (You do not have access to download this file.)
    gascolatordebris.jpg (You do not have access to download this file.)
    fuelpumpdebris.jpg (You do not have access to download this file.)
    Fuelpumpfilter.jpg (You do not have access to download this file.)

    Roger Lee
    LSRM-A & Rotax Instructor & Rotax IRC
    Tucson, AZ Ryan Airfield (KRYN)
    520-349-7056 Cell

      
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