Part 30 Re-Fitting the Magneto Generator Housing ...

Introduction ...

This page contains photos of the process of re-fitting the magneto generator housing to a ROTAX 912ULS engine (built August 2006).



ROTAX 912ULS re-fitting the magneto generator housing

Image 1

Start by re-fitting the anti-vibration mount that supports the ignition coils to the magneto housing. This is an image that was actually taken during disassembly rather than reassembly but appears to be the only photo I have of this step ...

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ROTAX 912ULS re-fitting the magneto generator housing

Image 2

Clean the mating surface on the crankcase that the magneto housing will seal to with flange sealant ...

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ROTAX 912ULS re-fitting the magneto generator housing

Image 4

Here you can see the entire mating surface cleaned ...

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ROTAX 912ULS re-fitting the magneto generator housing

Image 5

Note however that the little oil feed o-ring (5 x 2) needs to replaced / refitted ...

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ROTAX 912ULS re-fitting the magneto generator housing

Image 6

Here is the new o-ring on the bench. Note the light green colour ...

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ROTAX 912ULS re-fitting the magneto generator housing

Image 7

Now clean the mating face on the magento generator housing itself ...

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ROTAX 912ULS re-fitting the magneto generator housing

Image 8

Blast any residual FOD from the cleaning process away from the housing with compressed air, doing the same for the mating face on the crankcase ...

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ROTAX 912ULS re-fitting the magneto generator housing

Image 9

Here is the Rotax protection sleeve that protects the sealing surface of the magneto housing's crankshaft oil seal when it comes to replacing the housing ...

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ROTAX 912ULS re-fitting the magneto generator housing

Image 11

The protection sleeve is to be placed on the end of the crankshaft ...

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ROTAX 912ULS re-fitting the magneto generator housing

Image 12

Like so ... And covered with a light coating of GP grease ...

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ROTAX 912ULS re-fitting the magneto generator housing

Image 13

Next the flange sealant is applied to the mating face on the magneto generator housing ...

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ROTAX 912ULS re-fitting the magneto generator housing

Image 14

Applying it with a roller allows us to apply a consistent and even thickness of sealant ...

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ROTAX 912ULS re-fitting the magneto generator housing

Image 15

The magneto housing is now pressed home very gently being carefull to ensure that as the crankcase oil seal passes over the end of the crankcase no damage is sustained to the sealing surface ...

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ROTAX 912ULS re-fitting the magneto generator housing

Image 16

Here is the housing in position ...

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ROTAX 912ULS re-fitting the magneto generator housing

Image 17

As you can see the magneto housing was re-fitted with the stator in place. The mounting bolts are torque'd upto as per the Rotax Heavy Maintenace Manual / IPC ...

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ROTAX 912ULS re-fitting the magneto generator housing

Image 18

The P-clip that supports the generator cabling as it exits the housing is torqued's up ...

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ROTAX 912ULS re-fitting the magneto generator housing

Image 19

The last two bolts that require re-fitting are the two bolts that are fitted to starter motor mounting point ...

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ROTAX 912ULS re-fitting the magneto generator housing

Image 21

Here they are on the bench ...

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ROTAX 912ULS re-fitting the magneto generator housing

Image 22

And here they are refitted in the vicinity of the starter motor mouting point with nylocs on the back of them ...

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ROTAX 912ULS re-fitting the magneto generator housing

Image 25

Now the housing is in place the protection sleeve / guide may be removed ...

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ROTAX 912ULS re-fitting the magneto generator housing

Image 28

Another anti-vibration mount is to be re-fitted here ...

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ROTAX 912ULS re-fitting the magneto generator housing

Image 29

Here it is bolted to the housing ...

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