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Do we really have to open the crankcase in order to replace the freewheel gear? See the pittings in the video. Rotax maint manual just says "The free wheel gear, the pump gear pressed on- to the crankshaft and the timing gear under- neath it can be removed only after splitting the crankcase." 

Any alternative methods?

  • Re: Really open the crankcase for this?

    by » 2 weeks ago


     
     

    Hello Alexander,

    "Splitting of the crankcase" is necessary to remove the freewheel gear. Some instructions for gaining access to the freewheel gear can be found in the Rotax Heavy Maintenance Manual, Section 72-20-00, available here: Rotax Heavy Maintenance Manual. However, the instructions for removing the freewheel gear (after splitting the crankcase) are only found in the Rotax Overhaul Manual, which is not released to the public.

    Please note that special Rotax tools and proper training are required to perform this task as it is quite in-depth. We highly suggest you either receive training or hire a qualified Rotax technician to perform this task.

    Rotax Training: Rotax Training
    Rotax Tools/Parts: Rotax Tools/Parts

    Best regards,

    Rotax-Owner

     

  • Re: Really open the crankcase for this?

    by » 2 weeks ago


    Thanks for the reply. I am well aware of the implications of opening the crankcase. But this will incur not only many thousands of Euros for labour, but leaves me with an engine of 250 hrs with an opened crankcase and the risk of sub-optimal results and no flying this summer. 

    Thus the search for ways to circumvent this design flaw.


  • Re: Really open the crankcase for this?

    by » 2 weeks ago


    What one could do is to heat the small sprocket wheel and pull it from the camshaft. Then it is easy to pull off the freewheel gear - that is straightforward. To press the small gear back onto the camshaft, it is not advisable to simply apply pressure to the camshaft in its installed state, that is, on the engine housing. However, it should be possible if one builds a frame that reaches around the engine block to the oil pump side at the other end of the camshaft, to press the gear (after heating it) back onto the camshaft with pressure applied only to the camshaft.

    Has anyone ever done this before?


  • Re: Really open the crankcase for this?

    by » 2 weeks ago


    We know it has been done before, but it's not an easy or "approved" procedure and carries a high risk of causing serious damage. We cannot provide information on how to do it, but we will connect you with someone who has and may provide you with some insight.

    Stand by for their response.


  • Re: Really open the crankcase for this?

    by » 2 weeks ago


    That would be very helpful and very kind, thank you in advance


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