How much does it cost to overhaul a Rotax 912

So you're looking at overhauling a Rotax 912. Expect to shell out somewhere between $8,000 and $15,000 for a standard field overhaul. If you want the factory-certified zero-time job, that'll run you $14,000 to $18,000. Honestly, the final number depends on which model you've got (912UL, 912ULS, 912iS), what your local shop charges per hour, what parts actually need replacing, and whether you're doing a top-end or a full bottom-end job.

What is included in a Rotax 912 overhaul cost?

A full major overhaul means they tear it all apart, inspect everything, swap out all the mandatory bits, and put it back together to factory specs. The money breaks into three chunks:

• Parts and kits: Rotax sells a mandatory overhaul kit for around $4,000 to $6,000. That gets you gaskets, seals, piston rings, bearings, and all the stuff that wears out.
• Labor: Shops charge anywhere from $75 to $150 an hour. Figure 30 to 50 hours of work, so that's $2,250 to $7,500 right there.
• Additional repairs: Things like cylinder honing, valve guide replacement, or gear inspection can tack on another $1,000 to $3,000.

What affects the overhaul price the most?

The engine model and the core's condition are the big ones. The 912 iS (fuel-injected) costs more than the 912 UL or 912 ULS because of all those extra electronic bits and sensors. If your engine has a lot of corrosion, damaged gears, or a cracked crankcase, expect to pay 20% to 40% more than the base price. It adds up fast.

How often does a Rotax 912 need an overhaul?

Rotax says every 2,000 flight hours or 12 years, whichever hits first. But a lot of owners jump the gun if oil analysis shows high metal content, compression drops, or weird vibrations. A top-end overhaul (just cylinders and pistons) usually pops up around 1,500 hours and costs $4,000 to $7,000. It's worth keeping an eye on it.

Can you save money by doing a partial overhaul?

Yeah, definitely. A top-end overhaul is way cheaper than a full one because you're only swapping the cylinders, pistons, rings, and gaskets. That works if the bottom end—crankshaft, connecting rods, bearings—is still solid. You're looking at $4,000 to $7,000 for parts and labor. But, if the engine has a lot of time or known problems, skipping the bottom end might lead to a catastrophic failure later. Then you're really out money.

What are the hidden costs?

• Shipping and freight: Getting the engine to a certified repair center costs $200 to $600. Not fun.
• Core exchange fees: Don't send back your old engine? Some shops hit you with a $1,000 to $2,000 core deposit.
• Propeller rebalancing: After the overhaul, you'll need to rebalance the prop. That's another $200 to $400.
• Oil and coolant: Fresh fluids run $100 to $200. It adds up.

Checklist for budgeting a Rotax 912 overhaul

• Get written quotes from at least two certified Rotax repair centers. Don't just go with the first one.
• Ask if the quote covers all mandatory parts, labor, and fluids. Some shops nickel-and-dime you.
• Make sure the shop has Rotax training and a decent warranty policy. Otherwise, you're on your own.
• Request a bore scope inspection before the overhaul to see what's up with the cylinders.
• Budget an extra 10% to 20% for unexpected repairs. Trust me, stuff comes up.

Frequently asked questions