General Maintenance Practices on Light- Sport Rotax Engines

in Light-Sport Aircraft Engines

Some specific maintenance practices that differ from conventional certified engines is covered for background and educational acquaintance purposes only. Always refer to the current manufacturer’s information when performing maintenance on any engine.

Safety regulations must be adhered to ensure maintenance personnel safety when performing maintenance and service work on any engine installation. The following information should be followed while performing maintenance.


The ignition should be off and the ignition system grounded with the battery disconnected. Secure the engine against unintentional operation. During maintenance work that requires ignition on and battery connected, secure the propeller against unintentional turning by hand, and secure and observe a propeller safety zone. This precautionary measure serves to avoid any injuries in case of an unintentional start of the engine, which can result in injuries or death. Remember, as long as the ground-cable (plead) is not properly connected to ground, the ignition is switched ON (hot).

Prevent contamination, such as metal chips, foreign material, and/or dirt, from entering the cooling, lubricating, and fuel system during maintenance. Severe burns and scalds may result if the engine is not allowed to cool down to outside air temperature before starting any work. Before reusing disassembled parts, clean with a suitable cleaning agent, check, and refit per instructions. Before every re-assembly, check for missing components. Only use adhesives, lubricants, cleaning agents, and solvents listed for use in the maintenance instructions. Observe the tightening torques for screws and nuts; overtorque or too loose connection could cause serious engine damage or failure.

The following are some general maintenance practices that provide for safety and good technique:

  • Work only in a non-smoking area and not close to sparks or open flames.
  • Always use the specified tools.
  • During disassembling/reassembling the removal of any safety items (e.g., safety wiring, self-locking fastener) must always be followed with replacement of a new one.
  • Once loosened, always replace self-securing (locking) nuts.
  • Use clean screws and nuts only and inspect face of nuts and thread for damage.
  • Check the contact faces and threads for damage and replace if any damaged is detected.
  • At reassembly of the engine, replace all sealing rings, gaskets, securing elements, O-rings, and oil seals.
  • At disassembly of the engine, mark the engine’s components as necessary to provide for locating the original position of the part.
  • Parts should be replaced in the same position upon reassembly.
  • Any used components have wear patterns that should be replaced or matched if reused. Ensure that these marks are not erased or washed off.

To perform maintenance, the technician must follow the manufacturer’s instructions. Obtain, read, and understand the information pertaining to servicing of the light-sport or experimental engine.