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keithhickling(at)clear.ne
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 Posted: Wed Dec 26, 2007 11:18 pm Post subject: Fitting Rotax ring mount for 912uls |
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Merry Christmas everyone.
Can someone please tell me how to fit the ringmount for the 912 uls? So far I've disconnected the rear mount of the ignition modules so the mount can slide under that, and the bottom 2 coolant hoses, but I still can't get the mount past the starter motor. Or, if I lift it over the starter motor first then it won't get past the alternator. Is it necessary to remove the starter motor, or can the ringmount somehow be manipulated past it? It's a bit like those Chinese puzzles designed to drive you mad!
Many thanks,
Keith Hickling,
New Zealand.
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avgashead(at)btinternet.c
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| Posted: Thu Dec 27, 2007 1:37 am Post subject: Fitting Rotax ring mount for 912uls |
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Hi Keith, I had the same problem, but with the added joy of having to fit the cooling shroud as well.
You have to remove the starter motor and unbolt the ignition modules. Be careful not to allow the starter motor to disassemble itself as you remove it. Give yourself a good clear working space and lots of patience!
Richard Scanlan
-----Original Message-----
From: owner-europa-list-server(at)matronics.com [mailto:owner-europa-list-server(at)matronics.com] On Behalf Of Keith Hickling
Sent: 27 December 2007 07:09
To: Eurpoa List
Subject: Fitting Rotax ring mount for 912uls
Merry Christmas everyone.
Can someone please tell me how to fit the ringmount for the 912 uls? So far I've disconnected the rear mount of the ignition modules so the mount can slide under that, and the bottom 2 coolant hoses, but I still can't get the mount past the starter motor. Or, if I lift it over the starter motor first then it won't get past the alternator. Is it necessary to remove the starter motor, or can the ringmount somehow be manipulated past it? It's a bit like those Chinese puzzles designed to drive you mad!
Many thanks,
Keith Hickling,
New Zealand.
[quote] -- Please Support Your Lists This Month -- (And Get Some AWESOME FREE Gifts!) November is the Annual List Fund Raiser. Click on the Contribution link below to find out more about this year's Terrific Free Incentive Gifts! List Contribution Web Site: --> http://www.matronics.com/contribution Thank you for your generous support! -Matt Dralle, List Admin. - The Europa-List Email Forum - --> http://www.matronics.com/Navigator?Europa-List - MATRONICS WEB FORUMS - --> http://forums.matronics.com [b]
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budyerly(at)msn.com
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| Posted: Thu Dec 27, 2007 11:04 am Post subject: Fitting Rotax ring mount for 912uls |
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<?xml:namespace prefix="v" /><?xml:namespace prefix="o" /><![endif]--> Kieth,
Your fun has just begun. I have my Rotax dealer do my ring mounts, and it's worth it. When they make the mods, the warranty is not in question. However, if you want to do it yourself.
Remove the water pump cover and the lower pilot side hoses.
You've done the hard part of moving the ignition harness.
The starter can stay on, but access is better with it off.
The carbs don't have to be taken off, but it can help.
At this point getting the ring mount on is easy.
Next you may find that the ring mount doesn't fit snugly. Rotax sells a shim kit for the mount which allows a proper fit. See their parts list. Torque as indicated in the maintenance manual. The ring mount should not be flexed to install.
Unless you are changing the exhaust system from the stock Europa, you must replace the water pump housing lower left (looking forward) bent nozzle from a 80 degree to a 45 degree. This will allow sufficient clearance to position the muffler as the Fire Wall Forward (Euroopa XS) instructions direct. To remove the 80 degree nozzle, heat the housing carefully and rotate off the nozzle. I use a propane torch, and heat the housing uniformly (about 400 degrees F) until the nozzle just starts to move easily and maintain constant temp after the nozzle starts to rotate and continue the uniform heat until off. A nice piece of 1/2 inch stock stuck in the hole works well. Do not cock the nozzle or you will destroy the threads. If you have to, use a small pipe wrench. It is best to remove both the nozzles on that side for ease of installation and removal. You have to rotate the upper nozzle to turn the lower. (It's never easy!) You might as well take off the one you loosened to ensure a good seal. That's your choice. Clean the threads and reinstall with loctite 243 in the orientation which will allow the two lower pilot side hoses to fit through the V in the ring mount support. When you reinstall the water pump housing, replace your gasket and if necessary the compression washers. Please note the stainless bolt goes at the 6 o'clock position and make sure you have a good seal with a new or cleaned up compression washer. That bolt has coolant running around it and it will leak if not done correctly. Torque as indicated. Do not over torque. Again, consult with the Rotax parts list for the 45 degree part number.
Reinstall the coolant lines and protect your hoses with a heat shield. For better service, go to a racing catalogue and order aluminum heat sleeve to finish off the installation. Get enough heat sleeve to do the oil lines also.
Once the engine is modified as indicated above, the FWF assembly is straight forward. Some have left the coolant lines below the ring mount when using the older rounder style muffler, but even then, the muffler's heat destroys the lower hose. One guy rotated the 80 degree nozzle aft, and put a very long hose on the nozzle to clear the muffler. Not very neat, and made mounting the engine more of a pain.
It takes a long day to do it the first time. Go slow and take your time, don't force anything and enjoy yourself. It took longer to do this email than modify the pump housing.
Bud Yerly
Custom Flight Creations.
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keithhickling(at)clear.ne
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| Posted: Fri Dec 28, 2007 12:08 am Post subject: Fitting Rotax ring mount for 912uls |
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Bud and Richard and David,
Many thanks for your responses.
Unfortunately I don't have a Rotax agent nearby; I would have been very happy to have them fit the mount!
Bud, the bent nozzles from the water pump housing seem to already have a bend of around 40 degrees, certainly not 80 degrees - 2 photos attached with the standard Europa XS exhaust system temporarily fitted. The hose from the lower nozzle is disconnected. The clearance between the end of the lower bent nozzle and top of the silencer is 15 mm - is that sufficient? To increase the clearance a bit it seems I would have to rotate the bent nozzle upwards a bit.
I just wanted to clarify what you mean by an 80 degree bent nozzle - I presume you mean bent to nearly a right angle. If so, my engine doesn't have those. Maybe they have chenged them on recent engines? My engine serial no is 5647439. So I presume, if I have not misunderstood you, that I don't need to change the nozzle? Is that correct?
Many thanks for your help - I really appreciate your response and advice.
Kind regards,
Keith Hickling,
New Zealand.
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budyerly(at)msn.com
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| Posted: Sat Dec 29, 2007 5:43 am Post subject: Fitting Rotax ring mount for 912uls |
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<?xml:namespace prefix="v" /><?xml:namespace prefix="o" /><![endif]--> Sorry for the delay as my computer is acting up at the shop.
I see you have the 45 degree nozzle on the lower left exit from the pump. You're correct to presume that the nozzle need not be changed out. If you can bend the lower nozzle upward so that both cooling tubes go through the V in the ring mount that will give you about another 15 mm clearance. At about 30 mm, with heat shielding, you will be able to get a long service life out of your lower hose.
Bud Yerly,
Custom Flight Creations
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keithhickling(at)clear.ne
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| Posted: Sat Dec 29, 2007 3:40 pm Post subject: Fitting Rotax ring mount for 912uls |
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Bud,
Excellent, many thanks for your input. Much appreciated. Happy New Year to all.
Regards,
Keith.
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