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. |
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