Rotax SI-916 i-003R1 Original operating manual

02 July 2021 Current valid documentation see: 79-00-00
Revision www.flyrotax.com Page 1 of 15
Copyright - BRP-Rotax GmbH & Co KG. All rights reserved. part no. 898136
d06892.fm
SI-916 i-003R1 / SI-915 i-003R2
SI-912 i-004R3 / SI-912-018R4 /SI-914-020R4
This SI revises SI-916 i B-003/SI-915 i-003R1/SI-912 i-004R2/SI-912-018R3/SI-914-020-R3 dated 04 Nov. 2020
SERVICE INSTRUCTION
Purging of lubrication system for ROTAX®Engine Type
916 i (Series), 915 i (Series), 912 i (Series), 912 and 914
(Series)
ATA System: 79-00-00 Lubrication system
1) Planning information
To obtain satisfactory results, procedures specified in this publication must be accomplished with
accepted methods in accordance with prevailing legal regulations.
BRP-Rotax GmbH & Co KG cannot accept any responsibility for the quality of work performed in
accomplishing the requirements of this publication.
1.1) Applicability
All versions of ROTAX® engine types:
1.2) Concurrent ASB/SB/SI and SL
In addition to this Service Instruction the following Service Instructions must be observed and
complied with:
in general - all relevant Alert Service Bulletins (ASB), Service Bulletins (SB), Service Instructions
(SI), Service Letters (SL), Service Instruction - Parts and Accessories (SI-PAC) with relevance to
perform this maintenance, repair or overhaul task.
- SI-912 i-005 / SI-912-010 / SI-914-011, title “Oil change“, current issue
- SI-916 i B-001 / SI-915 i-001 / SI-912 i-001 / SI-912-016 / SI-914-019, title “Selection of suitable
operating fluids”, current issue
1.3) Reason
This document should provide further guidance for the lubrication system with respect to:
- purging
-venting
- to avoid air in the lubrication system
ROTAX®was informed of a limited number of engine failures in the field resulting from a lack of
proper oil purging after the engine had been first installed and /or the engine had been re-worked.
This Service Instruction should help to make sure that the engines do not suffer such engine fail-
ures in the field. As air can be trapped in the valve tappets and cause valve train failure it is very
important to complete these instructions in their entirety.
Engine type Serial number
916 i (Series) all
915 i (Series) all
912 i (Series) all
912 (Series) all
914 (Series) all

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Revision Page 2 of 15
Copyright - BRP-Rotax GmbH & Co KG. All rights reserved.
SI-916 i-003R1 / SI-915 i-003R2
SI-912 i-004R3 / SI-912-018R4 /
SI-914-020R4
SERVICE INSTRUCTION
1.4) Subject
Purging of lubrication system for ROTAX® Engine Type 916 i (Series), 915 i (Series), 912 i
(Series), 912 and 914 (Series).
1.5) Compliance
These guidance and inspections have to be performed
- before the next flight, following the installation of a new engine
- after re-installation (e.g. after overhaul)
- after lubrication system opened and drained during repair, overhaul and maintenance work
(e.g. push-rod, hydraulic lifter, rocker arm, cylinder head, ignition housing, oil pump, oil feed
lines)
NOTE: Not affected are the removal and replacement of components that do not drain the oil
pressure galleries.
These maintenance instructions shall be considered at any maintenance events, retrofitting, repair
and overhaul.
1.6) Approval
The technical content of this document is approved under the authority of the DOA ref.
EASA.21J.048.
1.7) Labor time
Estimated labor hours:
Engine installed in the aircraft - - - labor time will depend on airframe installation and therefore no
estimate is available from the engine manufacturer.
1.8) Mass data
Change of weight - - - none.
Moment of inertia - - - unaffected.
1.9) Electrical load data
No change.
1.10) Software modifications
No change.
1.11) References
In addition to this technical information refer to current issue of
- in general Illustrated Parts Catalog (IPC) and in particular:
Chapter 79-20-00
- in general Operators Manual (OM)
- in general Installation Manual (IM) and in particular:
Chapter 79-00-00
- in general Maintenance Manual Line (MML) and in particular:
Chapter 12-20-00 - section Test run of engine
- in general Maintenance Manual Heavy (MMH) and in particular:
Chapter 79-00-00
mWARNUNG
mWARNING
Non-compliance with these instructions could result in engine damag-
es, personal injuries or death.

d06892.fm
SI-916 i-003R1 / SI-915 i-003R2
SI-912 i-004R3 / SI-912-018R4 /
SI-914-020R4
SERVICE INSTRUCTION
02 July 2021 79-00-00
Revision Page 3 of 15
Copyright - BRP-Rotax GmbH & Co KG. All rights reserved.
NOTE: The status of the Manuals can be determined by checking the table of amendments.
The 1st column of this table shows the revision status. Compare this number to the one
listed on the ROTAX website:
www.flyrotax.com. Updates and current revisions can be downloaded for free.
1.12) Other Publications affected
None.
1.13) Interchangeability of parts
Not affected.
2) Material Information
2.1) Material
Price and availability will be provided on request by ROTAX®Authorized Distributors or their inde-
pendent Service Centers.
2.2) Company support information
None.
2.3) Material requirement per engine
Parts requirement:
NOTE: Additional new parts are only necessary if wear was found in the engine valve train.
Order only the current need in accordance with Illustrated Parts Catalog (IPC), current
issue.
2.4) Material requirement per spare part
None.
2.5) Rework of parts
None.
2.6) Special tooling/lubricants- /adhesives- /sealing compounds
None.
Fig.no. Part no. Qty/
engine Description Application
881920 1 O-ring set valve cover
consist of:
250285 4 O-ring 105x2.5 valve cover
430205 4 O-ring 6.4x1.8 valve cover

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Revision Page 4 of 15
Copyright - BRP-Rotax GmbH & Co KG. All rights reserved.
SI-916 i-003R1 / SI-915 i-003R2
SI-912 i-004R3 / SI-912-018R4 /
SI-914-020R4
SERVICE INSTRUCTION
3) Accomplishment/Instructions
-ROTAX
®reserves the right to make any amendments to existing documents, which might
become necessary due to this standardization, at the time of next revision or issue.
NOTE: Before maintenance, review the entire documentation to make sure you have a com-
plete understanding of the procedure and requirements.
Accomplish-
ment
All measures must be implemented and confirmed by at least one of the following persons or
organizations:
-ROTAX
®- Airworthiness representatives
-ROTAX
®- Authorized Distributors or their independent Service Centers
- Persons approved by the respective Aviation Authorities
- Persons with approved qualifications for the corresponding engine types. Only authorized per-
sons (iRMT, Level minimum 9-Series Service) are entitled to carry out this work
- Persons with type-specific training
General Further material on general inspection, maintenance and repair can be found also in relevant
Advisory Circular AC 43.13 from FAA.
Advisory
Circular
This Advisory Circular (AC) contains maintenance methods, techniques and practices.
3.1) Illustrated Parts Catalog - related information
3.2) Installation - related information
Proper design of oil line connections and setup for purging the oil system.
All work has to be performed in accordance with the relevant ROTAX®Instructions for
Continued Airworthiness (ICA) of the respective engine type.
See current Illustrated Parts Catlog (IPC) for the respective engine type.
mWARNUNG
mWARNING
As the lubrication system design is also airframe related, also consult the
aircraft manufacturer for proper procedures of purging and venting. All oil
system related parts which are not in the scope of engine supply have to
be evaluated for proper purging and venting by the aircraft manufacturer.
See Chapter 79-00-00 of the current Installation Manual (IM) for the respective engine
type.

d06892.fm
SI-916 i-003R1 / SI-915 i-003R2
SI-912 i-004R3 / SI-912-018R4 /
SI-914-020R4
SERVICE INSTRUCTION
02 July 2021 79-00-00
Revision Page 5 of 15
Copyright - BRP-Rotax GmbH & Co KG. All rights reserved.
3.3) Operation - related information
In general all operating limits as per current Operators Manual (OM) have to be observed. In par-
ticular the limits which have influence to induce air into the oil system like e.g. acceleration and
static roll angle.
Pre-flight check and oil level check.
3.4) Maintenance - related information
3.4.1) Purging of oil system
See Fig. 1 to Fig. 4.
- Verify that oil tank connections are connected correctly and secured, and that the oil cooler (if
fitted) is in the suction line (pos. 1 on Fig. 1) between the oil tank and the oil pump inlet. Verify
that the oil tank is filled up to the maximum level (to the top of the flat portion of the dipstick).
Additional oil (up to 0.5 liter) may be added to the tank for the purpose of this procedure.
NOTE: Consult appropriate engine Installation Manual for diagrams to identify oil tank and oil
pump connections. Older engines may be equipped with oil tanks that have oil ports in
different locations.
See Chapter 3 section 3.2, current Operators Manual (OM) for the respective engine
type. In particular make sure that the oil level in the oil tank is between the two
marks (max./min.) on the oil dipstick, but must never fall below the min. mark.
All work has to be performed in accordance with the relevant ROTAX®Instructions for
Continued Airworthiness (ICA) of the respective engine type.
mWARNUNG
NOTICE
Incorrectly connected oil lines to the oil tank or to the engine will result in
severe engine damage.
Step Procedure
1 Disconnect oil return line(s) (pos. 2 on Fig. 1) from the oil tank (915 i and 916 i: two return
lines).
NOTE: Do not disconnect the turbo scavenge return line.
2 Place the free end (915 i and 916 i with two free ends) (pos. 3 on Fig.1) of the return oil
line into a suitable container (pos. 4 on Fig. 1) below the engine.
NOTE: This step is a cleanliness precaution. Typically, during the purging pro-
cedure, oil does not come out from the hoses.
3 Plug open connection (pos. 7 on Fig. 1) (915 i and 916 i with two connections) on oil tank
with suitable air tight cap or plug.
4 Remove all of the spark plug connectors from the spark plugs.
5 For easier rotation of engine remove one spark plug from each cylinder.

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Copyright - BRP-Rotax GmbH & Co KG. All rights reserved.
SI-916 i-003R1 / SI-915 i-003R2
SI-912 i-004R3 / SI-912-018R4 /
SI-914-020R4
SERVICE INSTRUCTION
NOTE: It is recommended that the lower spark plugs be removed to help prevent foreign ma-
terial in the combustion chamber.
NOTE: The oil tank bayonet cap is not pressure-tight, some air can escape.
The pressure in the oil tank has to be maintained during the following steps
NOTE: Do not use the starter for this purpose. Fit propeller and use it to turn the engine.
mWARNUNG
mWARNING
Non-compliance can result in serious injuries or death!
Be sure that ignition is switched off prior to any engine rotation of the pro-
peller.
mWARNUNG
NOTICE
Prevent entering of foreign substance through spark plug hole.
Step Procedure
6 Optional: This step assists in the purging procedure but may be skipped if compressed air is
not available. The procedure may take longer without air pressure.
Using a compressed air line, pressurize the oil tank through its vent nipple (pos. 6 on
Fig. 1) (on the neck of the tank). Adjust the compressor outlet regulator so that the air
line pressure is between 0.4 (5.8 psi) and 1 bar (15 psi). Do not exceed 1 bar (15 psi).
mWARNUNG
mWARNING
Non-compliance can result in serious injuries or death!
Do not remove oil tank or cover before ensuring that air pressure has been
completely released from the tank.
mWARNUNG
NOTICE
The oil tank may become empty and as result introduce air into the oil sys-
tem. Pay attention to the oil level and fill tank as required.
Step Procedure
7 Turn the engine by hand in direction of normal rotation until the first pressure indica-
tion on the oil pressure gauge of engine instrumentation in the cockpit. Normally this
will take approx. 20 turns. Depending on installation it may take up to 60 turns.
8 Stop the pressurization. Allow air pressure to bleed off.
9 Remove the cap(s) (pos. 7 on Fig. 1) from the oil tank and reconnect the engine oil
return line(s) (pos. 5 on Fig. 1) to the tank.
Ensure that the suction oil line (pos. 1 on Fig. 1) and oil return
line(s) (pos. 2 on Fig. 1) are connected to the proper fittings on the
oil tank. If the oil lines from the engine to the oil tank are incorrectly
connected, severe engine damage may result.
Step Procedure
10 Re-fit the spark plugs. Restore aircraft to original operating condition.
NOTE: See relevant MML on spark plug fitting and correct torque. If need-
ed re-apply heat compound to threads.
NOTICE

d06892.fm
SI-916 i-003R1 / SI-915 i-003R2
SI-912 i-004R3 / SI-912-018R4 /
SI-914-020R4
SERVICE INSTRUCTION
02 July 2021 79-00-00
Revision Page 7 of 15
Copyright - BRP-Rotax GmbH & Co KG. All rights reserved.
3.4.2) Purging of turbocharger lubrication system on ROTAX®914, 916 i (Series) and
915 i (Series)
.
To verify the turbo oil scavenge system is functioning properly the following steps are necessary:
11 Residual oil may have accumulated in the crankcase. Return it to the oil tank by fol-
lowing the oil level check procedures in the relevant Operators Manual (OM).
12 Fill the oil in the tank up to the full mark on the dipstick.
mWARNUNG
mWARNING
Non-compliance can result in serious injuries or death!
Carefully check all lubrication system connections, lines and clamps for
leaks and security.
ENVIRONMENTAL NOTE
Protect their environment. Observe to bury no oil!
Dispose of oil in an environmentally friendly manner.
Step Procedure
mWARNUNG
mWARNING
Non-compliance can result in serious injuries or death!
Observe the appropriate safety precautions. Make sure that there are no
foreign items including tools in the engine compartment. Secure aircraft to
the ground appropriately and place chocks under the wheels. Secure pro-
peller zone to warrant safety for persons and property. Be sure to ap-
proach only from engine side of propeller. Permanently supervise engine
operation from a secure position. The cockpit must be occupied during the
testing by a licensed pilot or an authorized person to conduct test runs of
an aircraft.
ENVIRONMENTAL NOTE
Oil may spray out.
Use a container that will contain a potential rapid flow without spilling the oil.
Step Procedure
1 Disconnect turbo oil return hose (pos. 2 on Fig. 1) from the oil tank (e.g. banjo bolt
M10x1x19) and route the line to a separate container.
2Start the engine in accordance to the relevant Operators Manual (OM).

d06892.fm
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Copyright - BRP-Rotax GmbH & Co KG. All rights reserved.
SI-916 i-003R1 / SI-915 i-003R2
SI-912 i-004R3 / SI-912-018R4 /
SI-914-020R4
SERVICE INSTRUCTION
- Restore aircraft to original operating configuration.
3.5) Warming up period
NOTE: At a new installation or modifications to installation do not start the engine before all
installation checks are finished.
3 Observe oil pressure and oil flowing out of the disconnected hose.
NOTE: If oil is not flowing out of detached hose within 10 seconds, stop
the engine immediately and find the trouble. repeat the previous
steps until proper oil flow is observed. The engine must not be
returned to service before rectification
4 Fit the turbo oil return hose (pos. 2 on Fig. 1) on oil tank. See latest Maintenance Man-
ual Heavy (MMH) for the respective engine type or instruction of aircraft manufacturer
for ROTAX®914, 916 i and 915 i Series.
Step Procedure
mWARNUNG
NOTICE
Before commencing with the warming up period, the following job tasks
need to be performed.
Step Procedure
1 Ensure that all engine and actuation systems such as carburetor actuation, cooling
system, ignition switch and propeller are installed and tested O.K. according to spec-
ifications of aircraft manufacturer.
Step Procedure
2 Connect negative terminal of aircraft battery.
3 Start engine and observe oil pressure.
mWARNUNG
NOTICE
If oil pressure does not raise within 5 sec. after engine start, shut engine
off. Do not start engine before lubrication system is checked and purging
procedure is repeated.
Repeated test starts with no indicated oil pressure will severely damage
the engine.
Step Procedure
4 Run engine for about 7 min. at approx. 2500 rpm. Then warm up engine at 2200 to
2500 rpm depending on ambient temperature until an oil temperature of 50 °C (122
°F) is reached.
5Check oil temperature and pressure values.
6 Stop engine and secure aircraft against unauthorized operation.
7 Check oil level as per operators manual and refill as necessary. Refill oil level in the
tank to max. mark. Do not overfill, otherwise oil would exit through vent hole during
operation. At oil level check the max. mark must not be exceeded.

d06892.fm
SI-916 i-003R1 / SI-915 i-003R2
SI-912 i-004R3 / SI-912-018R4 /
SI-914-020R4
SERVICE INSTRUCTION
02 July 2021 79-00-00
Revision Page 9 of 15
Copyright - BRP-Rotax GmbH & Co KG. All rights reserved.
3.6) Inspect the hydraulic valve tappet for correct purging
See Fig. 5 and Fig. 6.
The following check procedure describes the correct method for checking the hydraulic valve tap-
pets.
3.7) Replacement of components
If a hydraulic valve tappet still malfunctions after several engine runs, it must be replaced and the
valve spring support must be inspected for wear.
All work has to be performed in accordance with the latest Maintenance Manual for the respective
engine type.
If the valve spring support indicates wear, replace valve spring retainer, valve spring support, both
valve cotters, valve and hydraulic valve tappet. Additionally perform a detailed visual inspection of
relevant valve train components of push rod, rocker arm and valve spring for abnormal wear con-
dition.
mWARNUNG
mWARNING
Risk of burns and scalds.
Hot engine parts. Always allow engine to cool down to ambient tempera-
ture before starting work.
Step Procedure
1 Remove valve cover on cylinder 1.
2 Turn crankshaft in direction of normal rotation so that cylinder 1 is set to top dead center
(both valves are closed).
3 Push down the rocker arm on the push-rod side with a force (F) of around 70 N
(15.74 lb-force) for about 3 seconds. You can using a belt tester, for example, to check
approximately how much force is being exerted. Repeat on other rocker arms.
4 Check distance between rocker arm and valve contact surface. Max. allowable distance
0.5 mm (0.02 in.).
mWARNUNG
NOTICE
If it is possible to push the valve tappets further than this limit, perform an
additional engine run for about 5 min. at 3500 rpm after refitting the valve
covers. To get the hydraulic valve tappets primed, this process can be re-
peated another 2 times.
Step Procedure
5 Repeat on all other cylinders.
Step Procedure
1 Inspect valve spring support (1). Measure the wear referring to the reference surface
(inner area of valve spring support) in radial direction (2) to outer side with a dial
gauge. Value t = max. 0.04 mm (0.0016in.). See Fig. 6. An exceeding of
max. 0.04 mm (0.0016 in.) is not acceptable.
NOTE: The valve spring support indicates a possible malfunction of valve
train caused by incorrectly or insufficiently purged hydraulic valve
tappets. At standard conditions no wear is visible even after a long
time of operation. If the visual inspection shows some wear on the
valve spring support surface, measure the actual wear with a dial
gauge.

d06892.fm
02 July 2021 79-00-00
Revision Page 10 of 15
Copyright - BRP-Rotax GmbH & Co KG. All rights reserved.
SI-916 i-003R1 / SI-915 i-003R2
SI-912 i-004R3 / SI-912-018R4 /
SI-914-020R4
SERVICE INSTRUCTION
Carry out further warm up and inspection of the hydraulic valve tappets in compliance with section
3.2 and 3.3 until all 8 hydraulic valve tappets are hard and the max. allowable distance is not
exceeded.
3.8) Test run
Conduct test run.
In case of uninstalled engines test run is accomplished with the mandatory test run after installa-
tion into aircraft.
3.9) Summary
These instructions (section 3) have to be followed in accordance with the deadlines specified in
section 1.5.
The execution of the Service Instruction must be confirmed in the logbook.
NOTE: Work on EASA certified parts might affect the EASA Form 1 and does require appro-
priate documentation by authorized persons. Repairs must be entered into the engine
logbook and also do apply for the EASA Form 1.
A revision bar outside of the page margin indicates a change to text or
graphic.
Translation into other languages might be performed in the course of language localization but
does not lie within ROTAX® scope of responsibility.
In any case the original text in English language and the metric units are authoritative.
3.10) Inquiries
Inquiries regarding this Service Instruction should be sent to the ROTAX®Authorized Distributor
of your area.
A list of all ROTAX®Authorized Distributors or their independent Service Centers is provided on
www.flyrotax.com.
See Chapter 12-20-00 of the latest Maintenance Manual Line (MML) for the respec-
tive engine type.

d06892.fm
SI-916 i-003R1 / SI-915 i-003R2
SI-912 i-004R3 / SI-912-018R4 /
SI-914-020R4
SERVICE INSTRUCTION
02 July 2021 79-00-00
Revision Page 11 of 15
Copyright - BRP-Rotax GmbH & Co KG. All rights reserved.
4) Appendix
The following drawings should convey additional information:
Fig. 1
Purging of oil system (916 i and 915 i Series)
1 Suction oil line
2 Oil return line(s)
3 Free end
4 Suitable container
5 Oil return line
6 Vent nipple
7 Cap or plug
8 Pressurized air connection

d06892.fm
02 July 2021 79-00-00
Revision Page 12 of 15
Copyright - BRP-Rotax GmbH & Co KG. All rights reserved.
SI-916 i-003R1 / SI-915 i-003R2
SI-912 i-004R3 / SI-912-018R4 /
SI-914-020R4
SERVICE INSTRUCTION
Fig. 2
Purging of oil system (912 i Series)
1 Suction line
2 Oil return line
3 Free end
4 Suitable container
5 Plug
6 Pressurized air connection
7 To oil pump
8 Return from engine

d06892.fm
SI-916 i-003R1 / SI-915 i-003R2
SI-912 i-004R3 / SI-912-018R4 /
SI-914-020R4
SERVICE INSTRUCTION
02 July 2021 79-00-00
Revision Page 13 of 15
Copyright - BRP-Rotax GmbH & Co KG. All rights reserved.
Fig. 3
Purging of oil system (912 Series)
IN
OUT
6
2
5
8
7
AE 912_0039a
1
4
3
Pressure .... max. 1bar ( 15 psi )Pressure .... max. 1bar ( 15 psi )
Relevant plugRelevant plug
Direction of rotation
on propeller shaft
counter clockwise,
viewed from the front
1 Suction oil line
2 Oil return line(s)
3 Free end
4 Suitable container
5 Cap or plug
6 Pressurized air connection
7 To oil pump
8 Return from engine

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Revision Page 14 of 15
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SI-916 i-003R1 / SI-915 i-003R2
SI-912 i-004R3 / SI-912-018R4 /
SI-914-020R4
SERVICE INSTRUCTION
Fig. 4 05449,05451
Purging of oil system (914 Series)
7
IN
OUT
7
4
3
1
2
5
appropriate cap or plug direction of rotation on propeller shaft
counterclockwise, viewed from the front
to oil pump
back from engine
6
pressure...max. 1 bar
(15 psi)
1 Suction line
2 Oil return line
3 Free end
4 Suitable container
5 Cap or plug
6 Vent nipple
7 Oil return line

d06892.fm
SI-916 i-003R1 / SI-915 i-003R2
SI-912 i-004R3 / SI-912-018R4 /
SI-914-020R4
SERVICE INSTRUCTION
02 July 2021 79-00-00
Revision Page 15 of 15
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Fig. 5
Hydraulic valve tappet
Fig. 6
Valve spring support
NOTE: The illustrations in this document show the typical construction. They may not repre-
sent full detail or the exact shape of the parts which have the same or similar function.
Exploded views are not technical drawings and are for reference only. For specific
detail, refer to the current documents of the respective engine type.
max. 0.5 mm (0.02 in.)
F
2
1 valve spring support
2 radial direction
1