How Rotax Builds Aircraft Engines

Rotax is well known for its line of aircraft engines, but these are just a small part of the company's engine-manufacturing business. Last summer, AVweb's Paul Bertorelli visited the factory and produced this engaging video of how the company builds its aircraft engines.

[@josipvrandecic2472]

We must not forget that thanks to this company, sports aviation has become accessible to people with average property status, and the quality is at a high level. Thanks AVweb.

[@stephenirwin2761]

I recently saw a video visit of the Rotax snowmobile engine assembly line. I did not know they made aircraft engines. Thanks for the great video!

[@peachtrees27]

Ambassador Bertorelli pulls off more awesomness.

[@mcfast52]

I was a Rotax manganic and visited that factory, it was a great experience.

[@michaeldougfir9807]

Nice video. Well made. Thanks for no music. You answered more questions about Rotax than I knew I had.

[@adhcms]

Excellent video. Clear and to the point without any unnecessary distractions. Thank you

[@PacoOtis]

What an excellent and well presented video! Thanks so much for not having background music!!! Once the engines go into the GA market there are a lot of wild card variables and would want specific data regarding failures to include disassembly by qualified people. Thanks for the video.

[@theobserver3346]

A Totally Excellent Video. Thanks for the Insight into the Factory ( :

[@wmc9722]

What a wonderful and well-crafted presentation!

[@nikmotionmix]

Really outstanding presentation and commenting of the Rotax factory! Thanks for sharing.

[@danipad7215]

The best report I ha seen so far !

[@rubiconnn]

My BMW F650GS Dakar has a Rotax 650 in it. It makes some weird noises, but it's the only thing on the bike that isn't falling apart after 70,000 miles.

[@brandonquenneville7330]

this is why i own rotax. looks top notch to me. :)

[@thomasl7917]

Brandon Quenneville yeah. Guess you don't own one

[@nickgood8166]

As ever Paul gives an information dense presentation with an industry leading high signal to noise ratio. Keep it up!

[@RoboTekno]

I enjoyed this video. Please make more like it :-) It's like watching "How It's Made".

[@campbellaviation7289]

kzbin.info/www/bejne/Z3nRnpmOl51oq5o you better have watched this

[@henryp9600]

Have a 2009 Aprilia Tuono 1000R Bike with a V-Twin Rotax Engine that feels like it could run forever. Refined company doing quality work, 18,000 miles and still runs beautifully.

[@StingFlight]

Superb video, sir! The Rotax 912ULS in my 2007 Sting LSA is coming up on 3,000 hrs now, without a major mechanical hiccup! My leak-down compression numbers (84-86/87) and take-off performance values are as good as they were at 200 hrs! I'll be buying a new engine--someday.

[@DanStratocaster1]

Wow. Impressive video. Great work.

[@azulpiano]

impresionante felicitaciones por algo son los mejores !!!

[@davidvanniekerk3813]

Baie Dankie/ Merci Beaucoup Mick B for this good video. Rotax is very fine engine. Their factory ppl looks very professional. I was looking for a Rotax Diesel.

[@plhamilt]

Great Video. Very enlightening.

[@souljahroch2519]

Thanks so much! As an olde school VW, & Porche mechanic, I've wondered what the difference was between them, and the Rotax, and if it's air, or water cooled? So, it looks almost identical to the air-cooled engines I work on, other than the water cooled heads, and judging from the fins on the cylinders, I'm gonna call this 1. A hybrid, and 2. An engine I can't wait to work on, and maintain. I LOVE the simple design 😁✌

[@spannaspinna]

They have watercooled heads on the 4 stroke donks

[@chrishenniker5944]

I bet you can put the turbocharged ones in a Volkswagen or old Fiat 500.

[@tomcoryell]

I think there’s a VW bus in OZ with either a jabiru or a rotax in it.

[@SailOnFlyBy]

This was an excellent production! Thanks for putting this together and sharing :)

[@phoenixmekhi6001]

i dont mean to be offtopic but does someone know of a trick to log back into an Instagram account..? I was stupid forgot my login password. I would love any tips you can offer me

[@bradytorin5699]

@Phoenix Mekhi instablaster =)

[@phoenixmekhi6001]

@Brady Torin thanks so much for your reply. I got to the site on google and I'm in the hacking process atm. Looks like it's gonna take quite some time so I will reply here later with my results.

[@phoenixmekhi6001]

@Brady Torin it worked and I now got access to my account again. I am so happy! Thanks so much you saved my account!

[@bradytorin5699]

@Phoenix Mekhi No problem :D

[@maSHEALY]

The vw flat 4 air cooled will never die

[@philipo9624]

I had a Foxbat amphibian with the Rotax 912- a wonderful motor for a seaplane, constant temperature , you could do splash and goes all day and it did not miss a beat.

[@lloydmorrisonii1373]

WOW, Outstanding quality! Thank you so much for this great information.

[@repentuklondonwatchman1373]

BEAUTIFUL WORK

[@usmangwdc]

good and very informative. ...

[@georges.]

Germany and Austria. Engineering and manufacturing artist colonies. BMW, Porsche, Audi, KTM, Rotax, Swarovski , Mercedes Benz.

[@rock3tcatU233]

And Japan is an engineering empire.

[@georges.]

@@rock3tcatU233 ya...ok. They are the great "copiers" they taught China how to steal tech and make it cheaper. How many recalls Does Toyota have? The car company that on Wednesday announced it was recalling 1.9 million Prius vehicles worldwide was the U.S. leader in recalls last year. The company recalled 5.3 million vehicles in 2013, more than No. 2 Chrysler, with 4.7 million, and nearly twice as many as No. 3 Honda, with 2.8 million. Just a sample....VW has beaten Toyota as the biggest seller of cars worldwide now...There's a reason.

[@terrystephens1102]

Excellent presentation, thanks 👍👏👏

[@josecarlospoggian149]

👏👏👏👏👏👏Spectacular!❤️

[@kopronko]

Thanks . We had the best Experience with Rotax so far !!! But with others we didn't . Jabiru failed when the valve seats jumped out , and the Arrow failed with the carburators and fuel pump . That's why we went back 2 Rotax !!! ! !!!

[@StingFlight]

Great video production! I love my Rotax 912 ULS--which has never had so much as a "burp" in 1,700 hours of flying! I've found that most "problems" arise when Lycoming and Continental "know-it-alls" think they 'know it all,' about servicing the Rotax engine. That's when problems begin.

[@kopronko]

AMENNN !!! ! !!!

[@stephenbonin3049]

Less surprises in a four than a two stroke engine.

[@kopronko]

Not necessarry ...

[@Farweasel]

The statistics are on Stephen Bonin's side there Kopronko. Be great if the new generation of light, clean and reliable 2 strokes that are hinted at every so often were to happen 'tho.

[@andrewjackson7476]

Airplane engines are small bore, but long stroke, right?

[@javidanjum486]

Well done

[@vaccumme]

Sir. Could you please clarify the Product used to seal the matting surfaces ? Ted.

[@Mrcaffinebean]

Love how you get into ever detail great video!

[@georgeparrott454]

Very cool

[@Video-tipsTv]

Very interesting!! Thanks!

[@ramkajirai4582]

good job

[@fredericmartin8758]

Rotax vends a prix d'or des moteurs et ça ne les empêchent pas d'avoir des problèmes de traitement thermique sur les tiges de culbuteur, des flotteurs qui coulent et des régulateurs qui grillent. Ils ont de la chance de ne pas avoir de concurrent.

[@kevinolesik1500]

this is an awesome video , thank you ! Do the US Military drone engines get made here too ?

[@souljahroch2519]

Kevin Olesik No

[@geraldestes2470]

gentlemen, rotax, thanks you.

[@evandromp4277]

Fantástico de rotax vídeo.... I'd like to work in this Hodak's engineer!!!

[@DrD21486]

Single cam? And carburetor? Seems very interesting, basic but functional I guess. I’m more of a car person but this is fascinating.

[@ikay2102]

Thanks for shairing this info and you are doing great job for pilot community :)

[@Vulcancruiser]

Talked to a guy who had put 1,800 hours on a Rotax all over the country. Burn was a little over 3 gph......great engines.........

[@car5car5]

Crank in pieces is old motorcycle technology, which is not used by bikes anymore. Last bikes, which used this design, Kawasaki KZ1000 had a problem of crank pieces turning against each other. To overcome the problem crank pieces were welded together by repair shops after assembly. Honda was the first smart bike manufacturer which stopped using this design and started using one-piece automotive style cranks.

[@yuk-erkmckirk9277]

Roller bearing cranks are way more reliable and require less oil pressure than plain white metal bearings. I have a 1980 suzuki 850 with a pressed up crank and 1 piece rods with 827000km on the clock, never have i touched the bottom end at all. Maybe it is just kwakas with the problem, never heard it happen to a suzuki and they have lots of roller bearing motorcycles.

[@jorditrevole272]

Old school for the best result!

[@dovetailup8916]

I have both , 2-strokes and 4 strokes---never had even a burp out of mine along with others in our flight park. Only engine outs was were due to lack of fuel...

[@georges.]

That's not supposed to happen you know...

[@Elektronaut]

Very interesting video!

[@garthrichert5256]

Why isn't the upper half of the gearbox housing 'web reinforced' to the crank case for strength?

[@chippyjohn1]

I think you got the harmonic damper and overload clutch back to front.

[@RajKumar-xk8hg]

Good👍

[@paulwiles2961]

Here in Australia, I am having lessons in a foxbat (rotax engine) a great plane to fly, but I have always been a bit of a nervous flyer. Then I watched this clip, and I felt a lot better, then I read stancurtins comments, and I felt a bit nervous again, then I read jason ensmingers comments and I felt a bit better again. Surely the rotax has to be safer than an older lycoming in a 1970s 152, which I had my first lesson in.

[@karenaples]

Paul Wiles Speedway

[@stevevassallo4323]

Thanks for sharing the swinging level of confidence from the world of ultralight.

[@patriotsfan1236]

I wouldn't say they are more reliable. lycomings most reliable engine io360l2a in the newer 172 s is absolutely more reliable and less complex than most rotax engines.

[@Alex-us2vw]

The Lycoming is definitely more reliable. Regardless of age the engines are generally overhauled around every 2000-2500hrs depending how far your willing to stretch the interval. Forgot what the overhaul intervals are on Rotax engines, but if I remember correct it was somewhere around 1200-1500hrs.

[@anthonycyr9657]

A friends 912 in his kitfox has over 2300hrs and is still going strong..

[@paulwiles2961]

Thanks ice

[@felixromero5907]

Does anyone know about rotax factory or shop engines in the US.? Im from Nebraska thanks..

[@Crazyhero-zi6yt]

+felix romero Move to Austria!

[@LK-pc4sq]

@@Crazyhero-zi6yt wish i could

[@VietVet-fh6ti]

I’d like to see the written text and sign off for the assembly of the aircraft engines.

[@kmuralikrishna1582]

Can we use BLDC hubmotor instead of Rotax engine..?

[@fatiado225]

Maravilha.Parabéns

[@crapper1]

always thought cause it wasnt a big major name and went on lsa airplanes it was sub par quality glad to see this and know they are just as good and can feel better knowing its a good powerplant

[@sportpilot2]

If you look at failure rate(failures per units operating), they are as good or better than Lycoming. This coming from a Lycoming owner.

[@gbigsangle3044]

The US military uses the 914 on the Predator drones.

[@MrKdr500]

No! the US is responsible for murdering civilians.....as they say guns don't kill people, people kill people.

[@stanleydenning]

I wish Rotax made a two stroke for Powered Paragliding. Powerful and light.

[@Farweasel]

Skydrive (uk) are a Rotax dealer but for the lightest engines seem to be selling (Italian) Cisco 2 strokes. I know little about them other than they exist, but it might be of interest to you as a start point Stanley?

[@MarkSmith-js2pu]

Wow, I want a Rotax hat.

[@silkyjones2626]

Great report, Paul. No mmbo jumbo like from Dan Johnson.

[@slapaleftyhard6231]

Dan Johnson is a Prince in aviation. Delete this stupid comment.

[@BrilliantDesignOnline]

Thanks Paul. Well done video. My main takeaway from this is that there is NO WAY an average owner is going to be able to do anything significant to the engine with a failure, unlike a Lycoming or Continental owner. All the special jigs for assembly show not a lot of consideration down the line. It is similar to car builders who do not take into consideration doing engine repairs. A car is GOING to have a internal part fail or get crashed and need repairs. Goes for aircraft engines too. I hate that cars are built by putting the engine on a frame and dropping the body onto it. Rotax may make pretty, accurate, reliable engines, but if you need special tools and jigs to reassemble it, another manufacturer will win in the long run. I subscribe to KitPlanes: what EAA SportPilot >SHOULD< be.

[@randyvanvliet226]

Same crap with German made cars... Once the motor is screwed together at the factory, it's never the same if technicians have to pull the heads for some sort of failure, or sticky lifters, etc. There's a very good reason when something fails on german engines, you get a new crate engine shipped from the Motherland to drop in. The QC is just not there with current technicians being able to keep assembly QC levels necessary, without the factory jigs.

[@sarabiacommander6984]

genial,!°

[@eternityseven6200]

Just curious. Was this video actually just a group of images from a magazine with a narrator reading the article? Asking for a friend..

[@rexjenson1119]

This was very interesting and...very impressive. I've got a little bit of time in a Flight Design. The Rotax start and Rotax shutdown seems so weird at first.

[@vaioskaliakoudas6388]

Can an Aircraft boxer motor be designed and manufactured in a SOHC/DOHC pattern?

[@davidjulian8536]

Yes, it could, but then it would be wider and heavier. An OHC engine can operate at higher rpm, but an aero engine doesn't need to do that.

[@obfuscated3090]

The torque limiter clutch/shock damper is VERY like the compensator used on Harley-Davidsons since the Panhead years.

[@michaelhunt1683]

zzzzzz........NOT

[@lutfourrahaman3759]

very nice rotex

[@majidmajid1848]

Hi what is the price of this engine pls

[@cr-us9ch]

Nice factory, but the engines cost way too damn much

[@betofutebol5272]

Seria bom facilitar mais peças e motor

[@mqbitsko25]

"Economy of scale....." Yeah, right. You can do two things with that "economy": Lower prices, or higher profits. It's pretty obvious which way Rotax chose to go. Those things are absurdly expensive.

[@randyvanvliet226]

$18,000 + for a 1350cc 912 ULS motor with a single speed gearbox. How does Yamaha build a 1500cc complete snowmobile for less money? There's a reason there are a lot of Experimental aircraft built with VW air cooled motors with thrust bearings, and no gearbox, for 1/3rd the price, or less. 2000 hours for a motor isn't much life. I wish VW would build motors for experimental aircraft, then we'd get some true economies of scale. VW built TDI turbo diesel motors, capable of 130-140 HP with planned motor life of 25,000 hours.

[@HimalayaHoon]

Supply and demand gentlemen. Why is a 4 cylinder Lycoming 50,ooo plus Australian dollars?

[@stancurtin]

I had 8 engine outs in 6 years of flying ultralights with Rotax. And, that was not uncommon on the field where I tied down (which had 150 untralights). Even the factory demo planes stuck several pistons a year. The care and assembly looks good here, but I've never seen that kind of failure rate in GA engines. I've seen a lot of people claiming the reliability is comparable, but that certainly was not my experience. As a pilot, I'd strongly advise a kit builder to really ask around and research an engine before they decide on it. And, always keep where you're gonna land in sight. :-)

[@billdoming]

Are you referring to 2 strokes or 4 stroke engines. Failures in the 912 and 914 series (4 strokes) in factory mounted LSAs are very very rare. You might see a few failures in E-ABs mostly due to builders mistakes.

[@stancurtin]

Yes. I flew several different 2 stroke Rotax engines in different ultralights (MX and Phantom). Because failure rates were so high, we accepted it as part of ultralight flying. We did all the recommended maintenance and used the best oil we could. But engine outs remained routine with Rotax. Kawasaki engines were far more reliable, but do to liability, they stopped making them available. I have no animosity toward Rotax, but it will take quite some years of good service records before I'd be convinced they have produced a truly airworthy engine. But I hope they have/do!

[@NoahDiamond-Firearms-LLC]

From my experience, most of these engines used on aircraft are not certified for aircraft and are "Subject to sudden stoppages". This does not mean they are not reliable, but they cannot be guaranteed for aircraft safety for those models.

[@Lownslow84]

stancurtin

[@Lownslow84]

July

[@chrishenniker5944]

I bet you can put these in a small hot rod, like a Volkswagen Type 1, Karmann Ghia, Fiat 500, or something similar. You need an adapter plate for the transaxle, a clutch and maybe a car flywheel. The turbocharged ones would make a lightweight car really shift like a rocket and get its skirts up quicker than a female flasher.

[@shyammalviya4761]

Please detail this engine parchasing this engine how

[@yellowhammer4747]

ROTAX ENGINES ARE EXPENSIVE BUT I TRUST THEM. SPENT MANY A HOUR BEHIND ONE IN THE AIR

[@Pushyhog]

Ill take that first one with the purple hair highlighter.

[@steinrich56]

In Australia, these are regarded as ......"Bavarian Time Bombs"........meaning that you never know when they will go "off".....!

[@georges.]

That's the same country that makes the Jabiru. Meaning, you never know if it will start. In America it means. keep that POS out of my airplane.

[@TeemarkConvair]

could AVWEB possibly crank the video settings up a notch past a blurry eyed 144???

[@Elektronaut]

I can view it in 1080. Maybe you have to wait a bit

[@AVweb]

It was loaded in 1080p and I can view it at this res. Check the setting and you should be able to as well.

[@StingFlight]

AVweb I had no problem at 1080p.

[@Voxboy876]

You chime in too bitch....but don't bother thanking people for helping you with your fuck up??.....ya fucking mook.

[@venezuelarotor7977]

Lástima que siendo el idioma español el segundo más hablado a nivel mundial, no tengamos una traducción para los que no somos hábiles en otro idioma, pero si consumimos productos ROTAX

[@majidmajid1848]

👍

[@Herr_Jehmineh]

Good ole Pole Burrrburrrally

[@pedetorbulet8521]

I want to buy I'm from Thailand

[@betofutebol5272]

Por que é muito difícil comprar peças de reposição do motor rotax

[@hmbpnz]

Something is weird with the voiceover audio, like constant buffer dropouts....or my computer is on the fritz....

[@crawford323]

Too bad the cost of the engines are effectively taking aviation far from the grasp of the hobbiest.

[@Vfh........y]

And bring back the 503.........dcdi

[@ibgarrett]

This engine is still WAY less expensive than a Lycoming or a Continental...

[@offlanders]

@@ibgarrett Maybe. A Continental Titan 340 costs about $29k and produces about 180HP. A Lycoming O-320 has a price tag of $47K and develops 160HP, Rotax's 915iS costs about $39k and develops 141HP. I'm not sure I'd say its "way less expensive" but merely on par with their competitors. To Rowdy Flyer1903 original point, I do agree the price does place it outside the reasonable expectation of hobbyist, especially when you consider the $39,000+tax price tag is for the non-certified version of the engine.

[@Rx7man]

I just can't see where the value is for that engine to be $39K... I mean they're building entire cars for half that price

[@davidc5027]

but just imagine the profits this company is garnering from the airplane engine line. I can't imagine this costing any more than 10k for Rotax to make.. However, it must have cost a lot of money for upfront development costs, for example. Looking at their fiscal report it appears lumping all the different types of engines and vehicles together, they are running at least 20% profit. So, can't say what kinds of profits specifically, but still interesting. You can read more here -> www.globenewswire.com/news-release/2019/03/22/1759198/0/en/BRP-Reports-Fourth-Quarter-and-Fiscal-Year-2019-Results.html

[@Ditypo]

why they not use lots of gaskets?

[@souljahroch2519]

Sandy Telfer The machining makes them irrelevant. They're essentially using a liquid gasket to get a complete seal. Olde school, air-cooled VW, and Porche engines are very similar. Just newer electronics(ignition), and a water cooled head✌

[@mikew4171]

What does one of these basic model engines cost (USD) ?

[@df3yt]

Rotax doesn't have a USD cost. It's cost is measured in Kidneys.

[@abidfarooqui-sla3301]

$15000 for 80 HP Rotax 912UL. These are aircraft engines. This video is meant to be addressed to aviation audience. The high compression 912ULS 100 HP is $18500, the Rotax 912iS fuel injected with redundant ECU system 100 HP is $22000 and Rotax 914UL turbo charged Carb one 115HP is $30000 and the newest Rotax 915iS redundant fuel injected turbo 141 HP one is $38000. Rotax has the best power to weight ratio of any proven aircraft engine in production. Thus for light sport and many experimental light planes it has a virtual monopoly. Many companies have tried t compete and largely failed. The only thing comes close to their reliability would be 1940's tractor technology based Lycoming and Continental aircraft engines. They are significantly heavier and direct drive so for light planes they are not suitable. Up to 90 to 120 pounds heavier for the same HP and with same TBO

[@lesliesmith9155]

Watch out lycomeing 😊

[@ORMA1]

Modern factory for ancient engines

[@juancarlosgutierrez1684]

cost o price of rota 915 motor:?

[@andrewmorris3479]

$37,000 USD.

[@flyingwithchristina]

I don't see the gold plating in them anywhere, that justifies thier price...

[@MrKdr500]

You sound like you have never owned a Rotax motor? they don't come any better.

[@phillycheesetake]

@@MrKdr500 Literally any modern automotive engine is better.

[@andrewmorris3479]

Philly Cheese Take Please. Take any automotive engine and run it at 5,500 RPM for 2,000 hours straight. I’ll stick with Rotax thanks.

[@phillycheesetake]

@@andrewmorris3479 Water-cooled derivations of car engines have about a 30% TBO advantage on similar Rotax models, and they also consume less fuel. It's simply stupid to suggest that Rotax knows how to build better engines than Toyota, or Yamaha, or VW, or any major car company. The only reason they don't swoop in and put Rotax out of business is because they have too much common sense to enter the aviation industry.

[@andrewmorris3479]

Philly Cheese Take But a car engine doesn’t run at 5,500 RPM continuous, that’s my point. I’d want a lot of testing done before throwing one in an airplane.

[@stevegarcia9098]

remember, guys, if it flies, floats or fucks, it's better to rent it.

[@sherali2298]

How much does is cost

[@DavidBerquist334]

Is ge prat and Witney rolce royce the bigest manufacturer of airplane engines

[@garthrichert5256]

I don't know if using Rotax in aircraft is a good idea. I may trust it in a brush cutter though.

[@StephenBrewer89]

The 2t rotax engines in the 90s seadoo disappoint me. Hate the inner crank seal leaks :/

[@randyvanvliet226]

They were the same in the 80's in Bombardier powered personal watercraft. I towed more than my fair share of buddies, PWC back to shore on the Colorado River on 3 day weekends with seized motors. Inner seal crank leaks = air leaks = run lean = seized motor turned to junk, and long weekend ruined.

[@jeetenderkakkar7570]

Hello sir What is rotax engine water