All information here is correct at the time of publishing to the best of our knowledge, but Rotax recommendations may change at any time without
our knowledge. It is the engine owners responsibility to ensure that the engine is fit for flight at all times. The information is provided here free of
charge and with no obligation from us to the consumer.
CONAIR SPORTS
ROTAX 2-STROKE MAINTENANCE SCHEDULES
The following maintenance is planned and necessary for Rotax 277 UL, 377 UL, 447 UL SCDI,
462 UL, 503 UL, 532 UL, 582’90 UL and 582’99 UL, 618 UL.
X
Details
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2
3
4
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25
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42
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44
45
46
47
48
49
50
Example at the end of
the routine
maintenance tables
Rotax recommendation
Carried out as part of ConAir Sports standard service packages
Service available at extra cost
Replace carburetor rubber(s)
Replace radiator hoses
Replace cable grommets
Replace cross shaft oil hoses
Ground run (if installed)
Level check of liquids
Re-torque cylinder head nuts (1)
Re-torque exhaust manifold screws (1)
Check rewind starter condition
Check rewind starter rope (10)
Check electric starter gear
CCBCT check
Inspect spark plugs (10)
Replace spark plugs
Check ignition system
Check and/or adjust ignition timing
Check security of condensors
Check condition of points
Check condition of generator coil
(points ignition engines)
Replace points & condensers
Replace generator coil
Check operation of damper box
Check & clean inside spark plug caps
(10)
Checking of V-belt tension
Lubricate ball joints
Replace exhaust muffler springs
Lubricate control cables (3)
Check propeller balance and tracking
(2,3)
Inspect propeller mounting bolts (3)
Clean and oil air filter
Check fuel filter
Replace fuel filter
Check carburetor(s) and re-adjust (idle
speed, cable tension…)
Clean carburetor(s) and check for wear
Replace jet needle and needle jet
Inspect carburetor needle
Check fuel pump (measure fuel
pressure)
Check gearbox oil level
Replace gearbox oil
Inspect rubber coupling
Re-torque gearbox backplate bolts (A
type gearbox only)
Check and adjust gearbox, preload of
springs (type A & B type gearbox)
Check cross gear oil
Replace rotary valve lubrication oil
Inspect cylinder head and piston crown
(4)
Inspect piston rings for free movement
(5)
Check piston diameter (7)
Piston ring: check gap (7,11)
Piston ring: check axial clearance
(rectangular ring) (8, 12)
Check cylinder diameter (7,11)
2
h
First
10
h
12.5
h
25
h
50
h
75
h
100
h
125
h
Every
150
175
h
h
200
h
225
h
250
h
275
h
300
h
5
y
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(6)
(6)
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(6)
(6)
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(6)
(6)
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(6)
(6)
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(6)
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(6)
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(6)
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(6)
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X
Details
51
52
53
54
55
56
2
h
10
h
12.5
h
25
h
Cylinder: check for roundness (7,11)
Remove, check and de-carbonise rave
valve (618 UL only)
Replace cylinder head gasket, cylinder
base gasket and exhaust gasket (8)
Inspect piston pin and bearing
Inspect crankshaft and replace outer
seals if necessary
General overhaul of engine (9)
Notes:
(1) and after every replacement of gasket(s)
(2) also after any damage
(3) according to instructions of manufacturer
(4) if carbon layer is more than 0.5mm thick, decarbonise
(5) if piston ring sticks clean and replace if necessary
(6) if used in very dusty atmosphere
50
h
75
h
100
h
125
h
150
h
X
X
(6)
(6)
X
X
X
X
X
X
(6)
(6)
225
h
X
250
h
275
h
300
h
5
y
X
(6)
X
X
X
X
(6)
X
X
X
(7) wear limit see Service Information 5 UL 91
(8) If cylinder has been dismantled
(9) To be carried out every five years or every 300 hours whichever comes
first. Contact authorized distributor or service center.
(10) To be examined after every 12.5 hours of operation
(11) Necessary only if piston rings are not freely moving
only
6
7
8
9
10
11
12
13
14
15
200
h
X
GEARBOX SERVICING
The following maintenance is planned and necessary for Rotax Gearboxes
100hr gearbox
Details
1
2
3
4
5
175
h
Remove propeller
Drain oil
Remove gearbox
Measure & adjust pre-load of shock absorber
Re-torque back-plate mounting bolts, remove, replace & re-loctite if
necessary
Inspect rubber coupling
Remove gearbox front
Remove main gear
Visually inspect gear and shaft
Visually inspect taperlock bush
If applicable replace massive washer
Re-loctite taper lock bush and re-torque
Re-assemble including new gasket if necessary
Re-fit gearbox and propeller
Refill gearbox oil and wire lock
A
B
X
X
X
X
X
X
X
X
X
X
100hr gearbox service
fitted to engine
A
B
C
E
X
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X
Re-torque T/L
bush
C
E
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
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Example:
A 503 on a Quantum that has done 400 hours should have had:
10 hour engine service and 10 hour gearbox service after the first 10 hours
50 hour engine service at 50 hours Total Time
100 hour engine service and 100 hour gearbox service at 100 hours Total Time
150 hour engine service at 150 hours Total Time
100 hour engine service and 100 hour gearbox service at 200 hours Total Time
250 hour engine service at 250 hours Total Time
300 hour engine overhaul and 100 hour gearbox service and replace all rubber parts at 300 hours Total Time or 5 years old
50 hour engine service at 350 hours Total Time
100 hour engine service and 100 hour gearbox service at 400 hours Total Time
SHOCK LOAD TESTING
The following is necessary for Rotax 2 stoke engines after a propeller strike (SLT)
Details
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
21
18
19
20
21
22
23
24
Visual check of engine
Where necessary remove and re-fit engine
Removal of flywheel
Check crankshaft radial run-out mag end
Check crankshaft radial run-out PTO end
Check crankshaft phasing (180)
Check flywheel woodruff key
Refit flywheel
Check ignition timing (points ignition engines)
Remove propeller and strip down gearbox
Visual inspection of housing
Measure radial prop-shaft run-out
Measure axial prop-shaft run-out
Remove gearbox front
Measure & adjust pre-load of shock absorber
Inspect rubber coupling
Remove main gear
Crack test gear set
Visually inspect gear and shaft
Visually inspect taperlock bush
Re-loctite taper lock bush and re-torque
Replace serrated washer with latest type as required
Reset pre-load on shock absorber
Replace gearbox gasket and refill with oil
Install propeller as necessary
277
X
X
X
X
X
X
X
X
377
X
X
X
X
X
X
X
X
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447
X
X
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X
X
X
X
X
X
Engine
462
503
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
532
X
X
X
X
X
X
X
X
X
582
X
X
X
X
X
X
X
X
618
X
X
X
X
X
X
X
X
A
Gearbox Type
B
C
E
X
X
X
X
X
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STORAGE CHECKS
These checks do not include the routine maintenance that needs to be carried out when the engine is installed, such as oil and filter change,
changing of spark plugs, coolant change, balance carbs or compression tests.
Storage Period
> 12 months
> 12 months
> 5 years
Rotax specify that an overhaul is required at this time, but
Work Required
< 5 years
< 5 years
Top end strip down and inspection
Decoke
Drain cooling system and flush, remove water pump
housing and refill fresh
Strip & clean carb
Check timing
Check spark plugs and caps
Where applicable check points and condensers
Check starter
Remove flywheel and inspect for corrosion
Inspect fan belt and pullies
Strip & inspect gearbox
Where applicable change oils (cross gear and
gearbox)
Check exhaust system & lubricate ball joints
Replace exhaust springs
Clean or replace air filter
Strip & inspect fuel pump
Operator to carry out CCBCT checks every 10 hours
Replace oil seals on crankshaft cross shaft
Complete strip and inspection of engine
Change all rubber parts such as hoses, crankshaft
oil seals, fan belt, carb rubbers, water pump seals.
(engine turned at
least
every
3
months)
(engine not turned
at least every 3
months)
if the engine is found to be in good condition and you are
happy, we will carry out a reduced inspection to establish
the serviceability of the engine.
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