Repair Manual for engine type 462 - 532 - 582 UL Edition: 10 1994 HISTORICAL DOCUMENTS - FOR EDUCATIONAL PURPOSES ONLY (ENGINES NO LONGER IN PRODUCTION: Information May Be Outdated) Bombardier-Rotax GmbH 4623 GUNSKIRCHEN Telefon: (0)7246/271-0* Welser Strasse 32 Telefax: (0)7246/370 recommended ATS 900,-- FOR INFORMATION ONLY. price: WITHOUT COMMITMENT TO ADVISE MODIFICATIONS. Part no: 899 081 Table of contents 1) Introduction:.................................................................................................................. 6 1.1) Engine number: ............................................................................................................................. 6 1.2) General notes: ............................................................................................................................... 7 2) Technical data: ............................................................................................................. 8 2.1) Technical data ROTAX engine type 462 UL: .............................................................................. 8 2.2) Technical data ROTAX engine type 532 UL: ............................................................................ 10 2.3) Technical data ROTAX engine type 582 UL: ............................................................................ 12 3) Tools and supplementary means: ........................................................................... 15 3.1) Standard tools: ............................................................................................................................15 3.2) Special service tools for the engine: ........................................................................................ 16 3.3) Special service tools and gasket set for reduction gearbox "A" and "B": ........................... 19 3.4) Special service tools and gasket set for the reduction gearbox "C": ...................................20 3.5) Lubricating-, securing- and sealing agents: ............................................................................ 21 4) Powerplant in aircraft: ............................................................................................... 22 4.1) Removal of engine from the aircraft: ........................................................................................22 4.2) Re-installation of engine into aircraft: ......................................................................................22 5) Disassembly of engine: ............................................................................................. 23 5.1) Removal of reduction gearbox „A“: ..........................................................................................23 5.2) Removal of reduction gearbox „B“: ..........................................................................................24 5.3) Disassembly of reduction gearbox „C“: ................................................................................... 25 5.4) Removal of rewind starter: .........................................................................................................27 5.5) Dismantling of electric starter: ..................................................................................................27 5.6) Removal of exhaust manifold: ................................................................................................... 28 5.7) Removal of ignition coils support plate and disassembly of rotary disk: ........................... 28 5.7.1) Engine type 462 UL: .......................................................................................................28 5.7.2) Engine type 532 and 582 UL: ......................................................................................... 29 5.8) Disassembly of water pump: ..................................................................................................... 31 5.9) Disassembly of rotary valve shaft: ............................................................................................31 5.10) Disassembly of BOSCH ignition unit: ....................................................................................... 32 5.11) Disassembly of DUCATI ignition unit: ......................................................................................33 5.12) Removal of cylinder head (type 462): .......................................................................................34 5.13) Removal of cylinder head (type 532 and 582): ......................................................................... 35 5.14) Disassembly of cylinders and pistons: .................................................................................... 35 5.15) Disassembly of crankcase: ........................................................................................................37 6) Cleaning of engine components: ............................................................................. 38 7) Inspection and judgement of components: ........................................................... 39 7.1) Crankcase: ...................................................................................................................................39 7.1.1) Measuring of crankcase: ................................................................................................. 39 7.2) Crankshaft:...................................................................................................................................41 7.2.1) Removal and inspection of crankshaft bearings: ............................................................ 41 7.2.2) Checking of crankshaft alignment:.................................................................................. 42 7.2.3) Radial- and axial clearance of conrod: ........................................................................... 43 7.3) Cylinder: .......................................................................................................................................45 7.3.1) Inspection of the cylinder: ...............................................................................................45 7.3.2) Cylinder bore: .................................................................................................................. 46 7.4) Piston: ..........................................................................................................................................47 7.4.1) Piston-to-wall clearance: .................................................................................................47 7.4.2) Piston rings: ....................................................................................................................48 HISTORICAL7.4.3) DOCUMENTSPiston - FOR pin: EDUCATIONAL.............................................................................................................. PURPOSES ONLY (ENGINES NO LONGER IN PRODUCTION: Information.........49 May Be Outdated) 7.4.4) Piston pin bearing: ..........................................................................................................49 7.5) Cylinder head: .............................................................................................................................50 7.6) Thermostat: ..................................................................................................................................50 - 2 - of 170 10-1994 Rm. 462-532-582 UL 7.7) Rotary valve shaft: ...................................................................................................................... 51 7.7.1) Disassembly of rotary valve shaft: .................................................................................. 51 7.7.2) Inspection of the single components: ............................................................................. 52 7.7.3) Sealing of rotary valve shaft: .......................................................................................... 52 7.7.4) Reassembly of rotary valve shaft: ................................................................................... 53 7.8) Contact breaker ignition unit: .................................................................................................... 54 7.8.1) BOSCH magneto generator SCP2 on ROTAX 462 UL and 532 UL: ............................. 54 7.8.2) Stator plate: ..................................................................................................................... 54 7.8.3) Wiring diagram: ...............................................................................................................55 7.8.4) Flywheel: ......................................................................................................................... 55 7.8.5) Ignition damping box: ...................................................................................................... 56 7.8.6) Adjusting of ignition timing: .............................................................................................57 7.8.7) Pole shoe breakaway gap:.............................................................................................. 58 7.9) ROTAX 582 UL with breakerless DUCATI dual ignition unit (DCDI): ..................................... 59 7.9.1) Brief description: ............................................................................................................. 59 7.9.2) Operation of the ignition unit: .......................................................................................... 59 7.9.3) Ignition switches: ............................................................................................................