OFERATORISIWANUA-L

f
ROTAX. ENGINE TYPE
I Sos uL
l
equippedwith breakerless
dual ignition system
and BING carburetor

EDITION: 121990
Thismanualcontains
i-po"t ffi
infolmation concerningyour engine. ft must remain
with
rl the engineat time of resale.
I

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 Modifi cationsor spccialapplications

i
ri

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 Section Index Page
l. genelalsafetypoints...............,..........
Importantprefacc, 5
2. Forcword....... 6
3, Fuel&oi1......................... 6
Mixingprocedure..... 7
4, Sbrting proccdurc,pre-st!-n
checkprocedure
................. 8
5. Break-inDroccdure...................-..... 9

ll

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 Danger!

This engine,by its design,is subjectto suddenstoppage!Enginestoppage

canresultin crashlandings.Suchcrashlandingscanleadto seriousbodily
injury or death.

Neverfly the aircraft equippedwith this engineat locations,airspeeds,

frorn whicha successful
altitudes,or othercircumstances no-powerlanding
cannotbe made,after suddenenginestoppage.

Warning!

Althoughtheseenginetypeshaveundergoneconsiderable durability te-

sting, thisengineis not a certifiedaircraftengine.Ithasnot receivedany
individual safetyor durability testing and conformsto no aircraft stan-
dards.It is for usein experimentaland ultralight uncertifiedaircraft and
vehiclesonly,in which an enginefailure will not compromisesafety.

Userassumes all risk ofuseandacknowledges

by hisusethat heknowsthis
engineis subjectto suddenstoppage.

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 1) Important preface:
Safctyi6 everyone'sbusiness.We haveincludedsomeof theimportantsafetytips here,but thelisr is
not complete.It would be impossibleto list every way in which onemay be injured. Pleasenotedre
following symbolsthroughour$e book.

. - S,A.FETYWARNING: Failure to obey a safetywarningmay result in injury to you or others.

I - INFORMATION vital to the operation or maintenanceof your product (this should also be
considercdnecossaryfor safety).

Lr) Generalsafetypoints:
' - Nevermix fuel in anenclosedalea,or wherefumescouldrcachan ignitionpoinr.

^' - Make sureall enginecontrolsareoperative,that you know on and off positionsof throttle
and ignition, that they are easily accessible,and rhat you can operalethem instinctively
without hesitation.

- Nevcrrefu€liffuel couldbespilledonhotenginecomponenrs.
Useonly saferyapplovedfuel
containe$and everEansportfuel in an unsafemanner.

- Checkenginesuspensionfaequently
aswell asfle driveconrponenrs,
fuel lines,wirtlg, and
flrel arrdair fllters.

A - Checkforfuelcontamination,airvents,etc.Prcte{tengine
whilenotinuseftornanycontami-
nation enteringfuel or cmburetionsystembut be sureto rcmove storageuotection befoe
startingengine.

^. - Maintainyourengineintopconditionandassume it'sgoingtoquitrunningatanydme.I-eave
yourself a wry out in lhe eventof unexpectedfailure.

- Never run the eogineon the grcund with fte gopeller tuming, unlessyou aredoing soin a
run up areanndcar observeanyoneor arythilg enteing thedutger area.An observerin a safe
placeis a definiteasset.

- Neverleaveyour aircraftorothervehicleunattendedwhilc theengineis running. Ifoperated

by someoneelseyou could be suedevenif the usewas unauthorizedby you.

- Keepan engine1ogandenterany unusualenginebehaviour.Do not fly unlessyou have

corected a given problemandrccordedthe correctionin the log.

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 2) Foreword:
TheROTAX engineis anair-cooledz-strokeengine,Carefulandextensivelytesteddesignandrugged
consEuctionas well asthe useof high quality parrsincreasoreliabiliry and durabiliry, Wirh proper
maintenanceandcareandwith theuseof suitablefuel andoil dreengineshould give you good service
for many years.

The ROTAX design incorporatesthe latest technical developments.Inorder to tate advantageof

futue developmentswe rcseNerhedghr romakemodificationsin theROTAX designwithout norice.

I NOTE: All fasrenersaremetricwith theexceptiooofthe internal threadof thep.T. O_cankshaft which

is 1/2" narionalfine ftread. It is to your advantageto readthismanualcarefully for theptotection
of yourengine.Theremaybesigrficant differencesfrom othettypesof fwo cycleenginesyou
may haveworked on.

Always usegenuineROTAX pafis.

I A Neue. r,ra enginewirhout proper loading,e.g. corect propeller. Refer section 17.

Section3
1) Fuel and oil:

A Fuelcoltaminationis a najor causeof enginefailure.Thebestplaceto avoidcontamination is at the

source.Oncein yoru fuel container',
a very harzadouspotendaledsts.
Usea cleansafetyapprovedstoragecorltainer.Filter all fuel enteringandleaving this container.Do
nolover- conlainer. allowforexparrsion.

WARNING: Gasolineis flan]mableandexplosiveundercertainconditions.Always performpioce-

dDresin a well ventilatedarea.Do not smokeor irllowopenflamesor spaJks
in tie vicillity.
Neve'raddfuel while engineis nuudDg.

Referto teclmicaldata- The engineis desigdedto operatea fuel fiitI.yJith2 Eaoil. Beswetouse
ploductsof at leastthe standardshownin thetechnicflldatasectioD.
If theengioeis to beusedinverted(with sparkplugspointingdown)selecta lubricantwhichfeatures
low carbondeposits.Oil residueteids ro drainto low points,i.e. sparkplug cavities.If rhisresidue
fails to burn clean during normadoperation,plug tbuling will occur, possible prc-ignirion also.
Manufacturersof suitablelubricanrswill guariurteetheir productsin writing.

Do not usefuel which hasbeenstorcdfor a long period of time.

Do flot leavefuel exposedto sunlightin translucentcontaine$.

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 3.1) Mixing procedure:

STEPno.1: Useacleanapproved container

ofknown
? volume.To help predilutetle oil, pour a
bit of fuel into container.

? STEPno. 2: I FiI k ro*r, urnoontof oil into con-

tainer.Oil musrbeapprovedfor air cooled

ffi
enginesat 50:1 mi;cingratio. Agitate
slighdy to dilute oil with gasotine.

? STEPno. 3: Add gasolineto obtaindesiredmixture

ratio (usehne meshscreen).

Fueimustbeof minimumM.O.N.
83 or R.O.N.90 octanenting.

= STEPro.4: Replace containercapandshakerhecon-

ffi
tainerthoroughly.Then usinga funnel
with a fine meshscreento preventthe
entryofwater andforcignparticles,trans-
fer mixture from containerinto the fuel
tank.

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 4) Starting procedure:
4,1) Pre-start check:

Beforcstartingenginereadsectiondcalingwith staningandcnginehtak-in thoroughly.The

servicelife of thc a[gineis largelydeteminedby howwcll youfollow theseinstsuctioqs.

Beforestartingenginebe sureyourinstallationis complet€,eosurethatall contols opffatc

easilyandsmootbly,andthatyoucaaoperatetheminstinctively.

A Alwaysensuethatyouarein a safcrun-upa!ea-

I Ensurctluottlclink.ge allowspistonvalvein carbEetorto bofiomin idle position,Screwout

idle specdadjustmcntsclgw (no.14,scction7) until carburcorpistod (no.3) bottoms.
Carefullytum in adjustment pisto[ andtum h a fudrer 3 to 3 1/2full
scrcwuntil it engages
tums.Checkif fuel line is conrlertedard tankvetrtis oDen.

4,2) Procedure;

Oncoldengineapplychokefully. Ensureidle position.(Openingthrotdewill greadyrcducc

chokeeffectlesultingin hardstardng).Makesureignitionswitchis on andthatyoucanshut
andthenpull throughvigolously.
it offinstandyifnecessary,Pull starterurtil firDllyengagsd

Aboveplocedueshouldberepeated until enginebeginsto firc. As soonaselginestafis,shift

thetbrotdeslowlyto low speedandrcmovechokeassoonaspossible(prolonged useof choke
cancauseengineto flood,)

Ifthc enginefails to startor operatesonly ononecylinder,chcckwhcthertheignitionwiring

is disconncctedor incore{dy connccted to thesparkplugconnectors
or to th€sparkplugsor
theignitiol s]vitchis in off position.

If Fecedingchecksdo notsolvetheproblem,rcmovethesparkplugsandinspecLwetspart
plugsindicatea floodedengine.

To corpct,replacewith dry plugsanddiscontinue useofchokc,Switchofrignition. Craok

fucl.
enginewith fully opendrotdo to clcarthc excess

Repeatstanproccdurc.

Dry sparkplugsindicatcno fuel in onginc.To inspect,reEovefloat bowl andcnsuefuel is

presentin suficietlt quantity,If not,inspectfuellevelin tank,fuelvalyeandtankycnt,I-ook
for blockageor obstruction. Corcat8ndrcpeatst{t proceduc,

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 Section 5

5) Break-inprocedure:
for aircraft installation (in other applicationsprcceedaccoldingly)

Thobreak-inhastobepcrtbrmed with drccngineinstalled,properlyloaded, i.e. propeuerinstalled,

matched for max. r,p.m. In caseof an aircraft, anchor thc plane to the ground. Rutr the engine
accordingto the following graph:

Engine
r.F.m, t0 t5 20 50 l2 5
H | 000 sec sec sec sec mlnmin min
,nta, f p.m.
(rcferpage32)
5,5
I

4,5
4
In.6
5,5
5

I r I r | | ll 2

0 r0 20 30 40 s0 60
illHi
^' h caseof a f&g3L!!g:i!c it is possiblethat the cooling air flow on groundis not cnoughto provide
the necessarycooling for a longcr period.Therefoleit is necassaryto observecarcfully the cylinder
hggl temperaturc(CHT) during breal in procedureto avoid overbearing.Beforc exceedingtie
maxiorumallowed CHT of 250 o C / 480 o F intenupt the run andcool down thc engine at idlc for
approximatelyone minute andcontinuewhereyou haveintefiupted.

. Be sure to use a safe run-rp area-to anchor aircraft at those points approved by the airframe
manufacturer,andto havesomeonepresentwho is ableto shutoff lhe engineinstandyandto prcvent
unauthorizerlpeopleentcring the duDgerarea.

^' Properclorhing, earplotection etc, shouldbe usedon any enginerun-up test.

T After this procedurethe idle hasto be adjusted.Then shorttake-offscan be conducted.After a few

shortfull-load take-offs,but not later than2 hourstotal running rime,the cylinder headnuts haveto
berc-torquedto 22 Nm (195in.lb.). For this procedurcthe cylinder cowl (if any)hasto be takenoff.

Enginemust be cool for re-torquingof head.

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 DiagramJor torque sequencewhen
arc in place
manifold,s
s-q
n ,v,
/T\ /T\
3\-/ \r 5
.7

NOTE: Considerboth cylindersasoneunit becausetheyarejoined by exhaustandintakemanifolds.

Usea crosssequencefor tighteningthenuts,startingfiom the center.EnsurEthal cowl scrcws
are torouedlessthanheadnuts.

6) Operation in flight:
It is rc{ommendedto usefull duottle during uke-off climb. Slight thrctde reducion may crcarea
lealer mixture aadmust be avoided.Selecta cruising speedwherethe engineis running smooth.

Do not exceedrraximun enginerpm (refersection18 technicaldata).

During cruise anddescendingit is very imponant not to createa lean condition wirh high rym and
low tluottleopedng.Thglessfreshchargetheelgine gets,themorehotrcsidualgasrcmainsin the
cylinder.This raisesdretemperatures to a cdticallevel. For this reason,you ncayalsoexpedence
higher exhaustgasamdcylinder headlempenturesat reduc€dthrottle openings.

Idling r.p.m. is 2000minimum. High idle sefting will rcduceenrichmentactionof startingsystemin

carburcto!(choke),makingcold startingdifficult.

engineshouldberunfor a few minutesat thelowestsmoothrunningr.p.m.to cool

kior to shutdown,
down,dependingon previouspowerselring.

Do|otidlgforFolonge.dpe odsasnomul chconditionat thispowersettingcancausgu necessary

carbondepositsandspurkplug fouling.Avoid runningconditionswhelegearboxshakingoccurs.

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 7) Carburetionr
Section 7
B
7.1)BINGCarburetor- typicaldescription:
(Note: this is not a pafis list)

a;\

n
tl
U
E
EI

n
ll16
E
-<-1
III.9

1 ) BIN G-doubleflo at carburetor

2) carburctorhausing -o{
3) carburetorpiston
%:%
4 ) jet needle
5) idler jet
6) needlejet
.gn
I to
14
7) miring tube 7 EI
8) mqitrjet ti A
o l sievesleeve
10) float needlevalve
I €a 0'o
1 1 ) float
12) Jloat chomber
r3) atr screw
14) adjustnErrtscrew
1 5 ) vefi ntbe
1 6 ) starting piston
17) rtd pwtp asa. (rype503 singlecarb.)
tg 12
@
\_l
1 8 ) fuel puntpassy.0!pe503 twocarb.)

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 The BING carburetoris a piston typecarbuetor wi$ float chamb€r.The carburetorcan be adjusted
byjet replacementof vaiious approvedsizes,by adjustingidle air/fuel mixtule screw,carbpiston stoD
adjustment, needlesizes,andneedleposition.

In no caseshouldjet changesbe madeby unqualifiedpeNonsor thosewho do not haveROTAX

technical inforDation to do so.

The airlfuel mixtur€ at idle speedis adjustedby theaa adjustingscrew(seeill. no. 13). The idle r.p.m.
is adjustedby thecarburetorpistor adjustment screw(ill. no. 14).

NOTE - theseidle adj[stm€nrs

inreract,soadjustingonemayrcquir€minoradjustment
of theothe!.

NOTE - On singlecarbenginesthe carburctorrnustbe in anexacrright anglepositiot in relation to

thecrankshaftin bothviews from top andfrom theintakesideto ensureanequalmixRle disEibution
to bothcylinde$ (seeill. below).

Changingparts shouldbe dore only after all othe! items have be€nchecked,and then bv an
two cyclemechanic.
experienced

A Ensurethat throtdecableand linkagedo not stick andthat carbpiston valvecanbe fitlly opeoedand
closed. Minor cablebacklashcanbe adjustedat cableadjustment screwandlock nur.

' Be certainthatthottle linkageis not affecredby engineor airframemovemenr.This couldchange

throttlesettings.

Airintakefiltrationand/ornoise
reductiondevicesmus!bein placeforpropercarburction.
Seesection
on specialoperatingcondidons.

Specialoperatingconditions,suchassevereclimateor altitudechangemaylequiredifferentjetting.
Contactyour dealer.

Ill. 13

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 8.) Exhaustsystems:
Considerableeffort has goneinto the designof the ROTAX exhaustsystems.Any changesmay
seveEly detedonte performance,rcliability, engine life, fuel economy,and the system'sability to
reducenoiseto acceptablelevels. Do not useotherexhaustsystemsclairrd to improveoverthestock
components.Do not makeany changesto the exhaustsystemsupplied.

I Vibotiou dueto imprcpersuspcnsion is anyexhaustsystem'swont enemy,Prcperlymountedand

maintained,your exhaustsystemwill provide a long servicelife.

A. Neverremovecoupling springwith a sharpobjectwhich could Dtarkthe spriDgmaterial.A rounded

scrcw-drivershankor a hook fashionedfroDl 1/8" baris idea.l.Safety-widngof springsis highly re-
cornmended. Exhaustball socketsshouldbe keprlubdcatedby a heatFsistaotgreaseto allow for
movementbelweenensineandnuffler.

9.) Propellergeartype"B":
9.1.)Mountinginstructions:

CarefuUy cleancontactareasbetweenoankcaseandgeatboxhousing.Cleanandde-grease
taperand1/2" interior threadofp.t.o. crankshaft,and interior taperofdrive gear.Installdrive
gearandlock washer,apply LOCTITE 221 on hex. screw l2'- 20 UNF x 50 and toroueto
60 No (530 in.lb.). Do not apply LOCTITE ro the taper!

Apply LOCTITE 648 on gearboxhousing,insert new O-ring andkeepit in irs locationwirh

somegrease.Apply LOCTITE 221on 4 studdrcads M8 andsqew rheminto crankcas€.Install
gealboxassemblyandrighter it with 4 hex. nutsM8. All 6 nutsM8 to bo toqued to 22 Nm
(195in.lb.).

T InspectconEctpositionof oil &ain plug (bottom)ondvetrtplug (top).

^' Securedrainplug with approvedlockingwhe.

Only applicablefor configurationwith separategopeller flange: Degreasegearprop shaft

taper,drcad andbolt Ml2 x 1,5LH (left hand)-Fit prope cr hubandapplyI-octire 221(vio-
let) on taperand thread.

ATTENTION: left hard thlead! Toque: 60 No (530 in.lb.)

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 NOTE: Prcpeller hub is rlreadedfor 6 x l/4" 28UNF- LOCTITE221
28 bolts (or 6 x M8). For proper bolts follow
propellermanufacrurer's specifications. 0
A fi[ appropriategear oil cL 5 or cL 6 (refer
technicaldatasection 17) into gearbox(for both posi-
tions of propoller shaft, above and below crankshaft
axis) up to lower oil level plug.
Securcventplug with approvedsa-
fety wire. oil levelplugs

Crarkshaft
p,t o. side

drainplug-- Ill. 14

NOTE: Gearboresfor aboveenginerypescanbefitted.alternativelywith prop shg belowor

abovecrankshaftaxis(seeako paragr.9.1).

9.2)Preflight Instructions:

A lrrgi'rnoN, es suppliedby rhetacrory,irespecrivewhethergearboxis separate

raomor rrtted
to engine,thereis nooil in thegearbox.

Tightcndrairplug,filt withspecified
oil toproperlevel.Insta ventplugandoil levelscrews.
Securewithapproved safetywfuebeforeuse!Checkrightness of bolrsandnuts.

9.3) Maintenance:
l. Every l0 operxti g hours:

Checkoil level on rcspectiveoil level screwarld securcagainwith wire.

Chang€oil after 1st 10 hoursof opcration.
Checkplopeller hacking cleararcc.
At everyoil changecleanmagneticplug.

Chang€oil every 100hoursor every 2 years(which occurshrst).

' NOTE: Mountingandmaintenance

opelations
mustb€ doneby skilledpersonnol
only.

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 10) Ignition System:

10.1) General:

The engine is equippedwirh a breakerless12V 170W DUCAII capacito!-dischargedual

ignition. It consistsof a flywheel magnetogenerato!,2 doubleignition coils widr integrated
control-circuir and2 externaltriggers(pick-up).

The 12-poleflywheelgenentoris anouterrotortypewith 12integatedpermanent magnetos.

The statoris equippedwith 12coils.8 of themareusedfor feedingauxiliaryequipmentand
4 areusedfor the dual ignition. The grey cableis foreseent'or connectionof a tachomerer.

10.2) Function of the ignition unit:

Twochargingcoilpairs fiftedontheg€neratorstatorand independautfromcach otherfeedone

eachignitioncircuit.Theenergysuppliedisstoredin theignitioncapacitor. At theEomentof
ignitiontheexternalniggerssupplyanimpulseto theconfolcircuirsandtheignirionconden-
sorsarc dischargedvia theprimary winding of rheignition coil. The secondarywinding sup-
pliestle highvohagefor theignitionspark.

^A ATTENTION:Whenflying balb ignirionsysrems

musrb€ swirchedON!

10.3) Checkingof ignition unit:

Beforeevery staJtthefunctionof the rwoiglition systemshasto bechecked.For checkingthe

ignitionunit rheenginemusrbeoperated at3000to 3500ymin andalrernately ignirionsystem
1 and2 mustbe switchedoff. The RPM-dop mustnor exceedmax. 300l/min.

I ATTENTION:With enginerunning thetriggercable (red)musttrotb€disconnecredfiom

rhe
electronicbox. This could desroy the electronicbox.

I gnitionsvitclres

q
shortingcable
10(black/yel.)
circuit I
J

circuit 2

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 10.4) Wiring diagram:

NOTE: Whenreplacingwidng on theignirion system,coDnections

mustbeasper widng diagram
below.
Electrontc box 5 pickup (ignition circuit l) l0 Shorting cables,
(ignition circuit I) 6 pickup (ignition cficuit 2) blacHyellow
Electronic box 7 trigger cable,red t 1 lighting cables,
(ignitiorl circuit 2) 8 chargiag cable,green tellow- yellodblack
eightlighing coils 9 charging cable,white t2 rc\).countef cable,
4 four charging coils Sray
na971s- 13 masscable, brown
14 ignitloa cables
l5 sparkplugconnectors
l 6 sparkplugs
1 7 shrink tube

After installing, all thecon-

nectionshaveto be prctec-
tedwith the suppliedshdnk
tubes.
17

r1l.17

\ l7i

I[. 16

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 10.O Sparkplugs:
Due to varying fuel propeties etc.,checkevery 10hoursof operation. Replaceasrequiiedor
annually, provided that sparkplug heatrangeand the carburgtorcalibration are colrect, the
spark plugs will have a hownish tinge ar the electrodesof betrLspa* plugs after full load
operation.

On engineswith singlecarbuetor,onesootysparkplug by itsefusuallyindicares a badplug

or faulty ignirion systemto thatplug i[ a soundengine.If bothplugsaresootywith oi I deposits,
carburationand air systemshouldb€ checked.On engineswith two carbuetors you should
switch the carburetorto tracethe problem.

t Alwayschangebothplugs.Nevcl interchange
plugsfrom onecylinderto theother.

If borh plugs have "white" electrodeswirh "melt" droplers, first suspecrlean mixrure. If
calibrationis corect andthereis no eviderrceof rnanifoldloaks,lack of fuel, or incorect float
s€ttings,don't chargethe plugs to a coldermnge.Checkif cooling systemis operaring
correcdy.

Al ef'rgr.,"ItOu: Heavyoit depositson theelectrodesandinsularormaycauseengineproblems,

exchangeregula.rlyevery 20 hours,or at any indicationsof trouble.

If, after clcaningor changingthe sparkplugs,you still havean ignition problem,checkto see
if only o e cylinderis affectedor both. Somethoughtto whatis commonto boil systems or
onlyonewill isolatetheproblenmoreeffrciently.Ifno exrernalfauttis found,theignitionunit
mustbe checked.

Nevercleansparkplugswith anabrasivecleaner.

Remembqto correcrlygapyourplugswith a wirc gauge(seetechnicaldara,secrion17). Spark

plugs must be torqued(seemain toquing specifications,section 18). If problemsoccur too
frequently,causemustb€deteminedandrcctilied.

'i --= z-,-',;

,-7, -7)
i=-,""'
$e..,,.^^l \*".,, ,,,r7 ',r""tt|

Overheated Normal
m.18 (light grey) .r9 (broi'niEh)

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 10.Q Lighting circuit:

In dre $atq 8 lighting coils areincorporated.The output is 170WA.C. and 13,5V effective
at 6000 Vmin. This altematilg c'urlsntcan bc us€ddir€cdy to feed A.C. consume$,or via a
rcctificr-rsgulator for losding a batteryandfeedingdirect curent consumon,

I To avoid the volragc to rise abovepermissiblelevels, a voltagercgulator must be uscd

To operateloadsrcquiring direct current(e.g.chargingbattery),a rcctifier-regulatoris requi-

red-

A rectifier-rcgulator, part no. 866 080, is available.For feeding lights only, this rcatifrer-
regulator carl also be usedwithout battery. In this casethEregularedRMS voltagc will be
betweonl1 and 12 Volts aslong asa minimum load of I ampis govidcd.

Ifa ban€ryis usedit hasto becapabloto absoft approx.I aDp.Drfuimumcontinuouscharging

load,evenwith full battery(suggestedminimumbatt€rycapacity:9 amp,h,resp.16amp.hwith
olectic starcr). Regulatedvoltageis 13.5!o 14.5volts.

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 866080
10,7)Wiring diagramfor rectifier-regulator
ATTENTION: @ To avoid excessivevollage ir conjunctionwith the
rectifireregutator866080,aconstantnfnimumballastloadof I amp
is lequircd(example:lamp12v 15W).

wiringiliagramin s circuit witho t battery

\E'

Il.2l

viring .liagrum in conjurrction vjtLLbaftery

f{.. t6n

.+ T E

-_
E
€ 'r
.r
T
T

I
yeUblack
\1.22
ground

wiring diagramfor €lectricstarter

seepage

---
---

-l-

yel,/black -l u.23.2
brown
Sround

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 10.8)Wipingdiagramfor rectifier-regulator
264870
(not limited to minimum of 1 Amperc con$r$ption)

wiing diagramin a circuit ta,ithoLt battery

\1.27

gr-een

rihite

jn
yel./black
rlt.24 E

ground

viri g diLgram i cotjunction v_i.JLLa bottery

I
-';

--
T
-r
Jel./black

ground I-
seepage2l
wiring didgramfot
elecbic sttrter tgg

nF ---

rx.%.2
L

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 Section11

L1)Electricstarter:
Two typesof electric startelscan be fitted !o casestartingprocedues especiallyin flight.

11.1)Electricstarterfitted to p,t.o.side:
Allows recoil starterto be retained,bur cannotbe fined on enginesusing ROTAX gear
rcductionunit.

11.2)Electric starter fitted on magnetoside:

For use with enginesurilizing ROTAX gearreductionunir. This elecFjc slanersystem

howevelelininatesrccoil startcaDabilitv.

11.31Batterv:

Either case,to ensurereliable starting,a baftery of at least 16 Ah (high-dischargebattery)

should be utilized. A higher battery amp- hour-mte would be prefemble. Cablessupplying
pow€r to the staiter from t}le batteryandto groundshouldbe l0 mm, flexible multi strand.
fuse16A
fr om rectifier-r egulator
(seesection11)
-=_
v<
- o
o
c
I o
starterbunon
-e- p Ilt.29
-L z
alectricslader

11.4)Starterrelay992819(Nidenso):

Startercontrol shouldbe via a power relay (suppliedwith srarrerkit) wired asshownabove.

For othe! makes,refer to respectiverelay wiring.

11.$ Fuse:
A 16 Amp fuse mustbe installedbetweenbatterychargingctcuit andmain powe! terminal.

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 Section12

12)Instruments:
Instrumentscanbe a valuableaddirionif they areof goodquality, correcdyinstalled,mainrained,and
if theoperatotunde$tandswhat theyaretelling him. Poor quality instrumentsshouldneverbe used.

Never usea tachometerdirectly conneciedto the ignition system.Usea tachometeroperatingon the

lighting coi.l.

AII iflsfuments rcquiring power sourcemust be ovedoadprotected.(Ref. section l l)

AII wiring and s€nsorleadsmust be properlyrouted andprotectedfrom vibrarion and abrasion.

For conect operiltilg speedrefer TechnicalData section.

Cylinder headtempemturesarc rakenat the sparkplug seat.Exhausrgastempetaturcsaremeasurcd

at 100mm (4 in.) from thecylindersleeve.Seesection17for temperatures.

12.1)Electronictachometer:

12.1.1)Introduction:

TheAviasporttachometer T8K12E,partno. 966072,hasbeenspecificallydesigned

to be connectedto the 12 pole flywheel genemtorusedon the Ducati CDI Systems.

The tachometermeaslres tie frequency of the pulses provided by one of the

transducelssupply winding where it is conflected.It doesl1otrequire any extemal
powersupply.It is connectedby two wiles withourpolarity.

Theindicatingrangecomesupto 8000r.p.rn.Theweightis 185 gram.Thepanelcutout

diametershouldbe60 o mm.

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 12.12) Connection to dual ignition system.

12.1.2.1)Tachometer966 072rflith resitor integratedin coil kit:

The generatorintegated in the

DUCATI dual ignition hasa spe- I
cial greycablefor tachooetercon-
c nection.The tachometet966 O72 E
!
hasto be fitted betweenthe giey
cableandmass(brcwncable).

On the coil kit 996 845 a I kO

resistor is connectedin seriesin
front of the grey cable(iU. 30/1).

12.1.2.2)Tachometer966072 with externallyfitted r€sitor:

In case of a short-circuit in $e
cableleadingto thetachometer this
resistoris foreseento avoidigni-
tion troubles.If thisresistoris de-
fective,itmust beremoved.In rhis
casecontactyour dealer.

Then this resistor in fiont of the

greycablemustbereplacedby a 1
kQ resistor866466andshrinktube
860621andbeinstalledin thegrey .3012
cablein series-connection (seeill.
302).

12.1.2.3)
Tachometer
966074with intecratedresitor:

If thelew tachoneter966074 is E
used,no suchresistorhas to bein-
stalled (alrcady integated in this E
tachometer). Referill. 30/3. t

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 966072hasarcd labeloa irs backsid; drcnewtacboEeter966()74hasthe
Thetachometef,
but a bluclabeloa its backside,
sameextemalappeararce

Thetachometer will indicatecorectrpmevenif oneof thetwo ignitionsysteDsis tumedoff

for ignitiontcstingproc€durcor a transduccr
failule happcns.

12.13)Calibration:

A calibrationpotentioE€ter is locatedinsiatethoinstruDenlThc adjusrmcnt holeis

coveredby a rcd labelon tachometcr 996 072 anda blue labelon the tachomet€r
996 074.It is possibleto coEectthe scalefactorby colnoctiongthetachometer in
parallelto a rEfererceinstrumeltor by usinga pr€cisiotrmechanical,opticalor
electronictachometer.

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 12,2)Hour-neter:

The hourmetcrpart no. 966 075 is suioble both for en-

ginesv/ith contact-breakerignition andelectronicigni-
tion ur[t.

A tachometer,rectifier or auxiliary loadscanbe

alsoconnectcdto theseouputs without interfe-
rencewith the hourmeter.

The symbols"+" and "-" on the black of thc in-

strumentdo not needto be observedasit is AC
powered.

Ilt.31 Powersupply:............6-100
V AC o!DC,
6 nrA. max.
t
E 128g.
weight:......................

Il1.32

9ll

lk
litlf -
fi(F
r$r
\
I11.33

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 13) Specialoperating conditions:

13.1)Water:

On water opeiationis a realpleasantexperience- usually. However,therearedangersto your

engineyou won't experienceon land. Someofthese dange$ are watet ingestionon take-off
or landing due to spray and splash,corrosion,electrolysis,and, wolst of all, unintentional
submersion.

Al neariogs,cralkshaft etc.,arehighly susceptibleto corrosion.Syntheticoits, althoughgoodlu-

bdcants,often att act moistrre ratherthanrepel iL

A well desigaedand well maintainedair intake system(e_g.ROTAX intake silencer with

K & N oil imFegnated air frlter) will help to preventwater ingestion.

13.2)Noise:
The air intake silencer kit will provide significant engine noise rcduction. Further noise
reductionmay be obtainedby theuseof alr after-mufflerkit. Be awarethat modificationsw l
reqnire a differcnt carburetorsetting.

Enquire at your dealerfor mo.e infomation, andconsult ROTAX sparepartslist.

13.3)Winter:
f Winter can qeate additionalproblemssuchascarbureto!icing, ftozen gashnes,higher air
densitiesetc., which rnay affect carburetorcalibrationandrequirelonger warm_upperiods.

13.3.1)Carburetor icing:

Distinguish betweentwo kinds of carburetoricing,

13.3.2)Icing due to water in fuel:

I Waterin fuel will accumulateatthelowerpartsof thefuel systemandleadsto freezing

of fuel lires, filtersorjets.

13.3.3)Icing becauseof high air humidity:

I Carbicing dueto hunidity may occuron tie ibel exit andon thecarbpiston andleads
to performanceloss andchangesthe mixtue.

Effecrive rcmedyis possibleonly by preheatinginrakeair.

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 13.3.4)Remedies:
- -
Fuelling without aacesof water (useshammyasfilter).
- G€nerouslysizedwater separator.
- Fuellinesroutinginclined.
prevenr condensationof humidity, i.e. avoid tempemture
differences between
aircraft andfuel.
- Add up to 2 7aisoprcpyl atcoholro the fuel.

I ATTENTIONT Fuels containing dcohol always carq/ a small amount of wat€r rn

solution.In caseof tempentue changesor iflcleae of alcoholconteDtjwater
ot a mixture of alcohol andwater may settleandcould causetroubles.

14) Maintenance:

14.1)Maintenanceschedule:

^. WARNING:

1) Maintenanceon enginesand systernsrequiresspecialknowledgeand tools. rt is therefore

rccommendedto havetheseworks performedby authorizedservicecentersor dealers.

2) Disconnectsparkplug leadswith a tuming motion for all maintenanceandinspecrion

procedues.

3) Puttingspa* plugconnectorbackon, makesurethatsparkplug teminal is ighr on

plu8.

t Servicetimesarebasedon averageuse,ilssatming engineis run at leastonceper *,eekfor a

normalduty cycleor averageflight. Total Linreb€foreteardownis dererminedby thefiequen_
cy alldconditionsofusage.Ifthe enginei snotgoingto beusedfor aperiodof Zmonthsor more,
consultstorageptocedrresin this section.

AJter initial break-inperiodcertainirspectionsand checksmust be made to ensureall

componentsandsettingshavercmainedtight andarewithin the specifiedtolerance.Failurc
to do so could leadto ptematurcenginefailurc.

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 POST BREAK-IN INSPECTION CI]ECK LIST

Enginetiming check

Sparkplug(s) condition

Carburetoradjustrnent

Engine headnuts

Engine suq)ensionnuts

Tighten a.llloose bolts, nuts andlinkages

Muffler attachment

Engine cooling system

Air filtration system

Fuel filtration system

Elecaical wiring (looseconnections,strippedwires, damagedinsulation)

Operationof lighting system

We highly recornmendtlat you haveyour dealet sign tiis inspection.

Date of Break-in inspection Dealer signature

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 14.2)Rewind starter:

Checkcord condirionevery 10 hours. Replacewhen wom or frayed.

To changethe safter rope,follow theprocedureoutlined(the numbersstatedin bracketsrefer

to theillustrarion).

First removethe rewind starte!assemblyfrom the engine.

Second,removerhesnapring (0, loopspringO, circlip O, pawl lock @,andthepawl 6.

Pull out the starterrope fully to the end,hold stanerhousingO andrope sheaveO together
in
rheirposirion.Thercis anopeningin thercpesheave.ThekeyclampO visiblein theopening
hasto bepushedoutin theoppositesense of thepulling dircction.pull theropeoutoftheropi
sheave.

Theninsertthenewstanerropeinto theropesheave, fir thekeyclampin thesamepositionas

ir wasandpushir ro be tight.Refirthepans6, 6, O, @andO.

/l WARNING: Do not rcmovespringcontainerO, this mightcauseinjunes.

Do nor operatethc engineif the rc$/ind starteris defectivc-
Most starterproblemsare due to improperopemfion.

/.,-:-:-,
--l==-!*Y==

ebe@ o0

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 14.3)Coolingsystem: V-bElt
deflection
Inspectfan belt tensionevery 10 hours.Replacebelt I + 10 m m - -
iffidyed or if it can no longe! be tensioled to specifi- .35 + .39 in.
cation.

The tension of the V-belt can be adusted by shims

between the V-belt pulley half andthe fan (resp.the
protectionsheaveon 503). Thev-belt is co(ectly ten- F= 5 0 N
sionedwhen it can b€ depress€d9 - 10 mm (.35 + .39 11 tbf
in.) wirh nomal finger prcssure "F" (in the middle
betweenthe 2 V-belt sheaves).

14.3.1)Mounting of V-Beltr Ilt.35

Install thefan (without V-belt) asper illustration .

Placc V-belt diagonally betweentwo bladesof the fan, tum
the fan until the V-belt hasmovedinto the pulley. Fix V-belt pulley and
startingpulley loosewith oneof the3screws.Put V-belr in thepulley grcove andtur:n
cnnkshaft irr orderto tensionthe belt andto centerthe pulley on the flywheel. Now
the 2 remainingscrewscan be htted.
Sclewtorque:22 Nm (195in.lb.).

^' ATTENTION:Onenginestype503neverput adjustmcnt shimsbetweenprotection

sheaveaadfan,becausethismightcausebrreakage.
Alwaysusefan holding
c tool,panno.876357.Thebeltmusrbemarkedbeforeremovalandreinstalled
; in same.direction.

possible shims storage

\,vbcn$ing new belt

edg e Etpe
503 only

far loldilg tool

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 14.4)Engine headnuts:

Afier break-in inspection they requirc only annual check. For re-torquing, see break-in
procedllle(section5).

nuts:
14.5)Enginesuspension
Inspect visua.lly regdarly (pre-flight check), Re-rorqueannually. Check procedruewith
airframemanufacturer.

14.6)Air filtration system:

dependingon rypeused(scespecialopemtion
Inspectfrequently(10 hours)for cleanliness
conditions.section6).

14.7)Fuel filtration systenr:

Checkat leastevery10hours(seefuel mixturesection3). Ensurecleanfuel at all times.

14.8)Checkfor carbon build-up and ring condition:

After approximately50hou6ofuse,thecombustionchomberlnayr€quirede-carbonizing. To
inspect,removeexhaustmanifoldandcheckfor depositson pistoncrown.Decarbonizing is
is
req0iredifdeposit thickness in therangeof 1 mm (.04 in-). On re-assembly
of manifold,
replacegasketsif necessary.

Re-torqueaflerfirst l0 hoursof operatior.

is consideredto
De-carbonizillg bea tecirnical
operation
andshouldtherefore beperformed by
an authodzei servicecenteronly.
To cherk for piston rings sticking in grooves,move pistoN lateially ro determineftee
movementof thetop dng. Ifpiston ringsarestuck,consultyour servicecenter.

14,9)Piston pin bearing:

Thc pistonpin is supportedin the con

rod eyeby 3l needlerollers,withouta
cage.

For disassemblya specialpiston pin

pullerandparticulaltrainingforitsuse
Pistondisassembly
is necessary. is all-
owed to be doneonly by an authorized
workshop.

m.37

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 14.10)Gear box:

15.10.1)To be performedevery l0 operatinghours:

Checkoii levelon respective

oil level screward secureagainwith lock wire.
Changeoil afterlrsr 10hoursof operation.
Changeoil every100hoursor every2 years(whicheveroccursirrsr).
Checkpropeller clearanceand tracking.

14.11)Storage:

If yourengineis not.goingto bemn for a periodof2 moDrhsor more,celain precautionsmust

betakento protecttheengineandfuel systemfiom heat,direct sun,corrosionind theformation
ofdeposits.The foilowingschedule is a guidefor storageprocedure:

14.11.1)Internal enginecomponents:

Removeirir filharion system,stanengineand allow to idle. Using ar oil_can,flood the

engiDeby injecting oil throughthe carburetortill the enginestalls,thenpilceed with
fuel systemdraining.

14.11.2)Fuel system:

Drain float chamber,renovefuel from tank,drainfuel lines.

-A. FoUowilll snfetyNles arncl

do not run for a ptolongedperiodaboveidle.

14.12)After storagecheck:

Inspectengineandengineenvironment for possibleforeignnuterials.Ensurealrresidueoil

is drainedor temovedby crarkingthe engine,and sperkplugsarecleanand and properly
galrped.Refill fuel tank,purgefuel line of air.proceedwith srartingprocedure
lsecdon4).

15)Tiouble shooting:
YourRorAXengine requiresbasicnllytwo essenrials ro run:sparka.d co''ecrfuel/airmixture.The
majorityof problemsquiteofrenarea simplelackoforle or theother.Org4ni29 y9ur.59lf
andfollow
a setpattemto eliminatecorDponents
to find your fouble.

Fuel:srafiby checkingthesupply(rank),fiffings(loose),filter (clogged),

floatchamber(fouled),jers
(blocked).

Spark: try newplugs.

koblerns of a more complex naturearebestleft to a RorAX enginerechnician:seeyou, dealer.

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 Section16

16) Engine repair log:

Recordany repairsor serviceon your ROTAX engineanduseas a reference.

PuchaseDate:

First Use :

Break-in Inspection:

Repair date Summary of work done

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 Engine repair log: cont.
Repair date Surnmaryof work done

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 Section17

L7) Technicaldata:

DESCRIPTION: twin cylinder-,two strokeOtto engine,lublicatedby fuevoil

mixtule,air-cooledby fan

BORE: 72,0mm (2,84in.)

STROKE: 61 ru! (2,40in.)

DISPLACEMENT: 496,7c.c. (30,31cu.in.)

COMPRESSION RATIO: 10,8

/rha^sri^rl\ pcakpower
r.p.m.
POWEROUTPUT: singlecarb.: 34,0kW (46 hp ) 6500
dualcarb-: 37,0kw (50,0hp ) 6600
MAX. RPM for all abovetypes6800l/min.

CYLINDER: 2 light alloy cylinderswith castiro[ sleeve

PISTON: aluminiumcastpiston witl 2 pistonrings, one semi-trapezdng

(top) andonelectangularring (bottom)

PISTON/CYLINDER CLEA- 0,07+ 0,08mm (.0028+ .0032in,)

RANCE:

TEMPERATURES CHT: (cyl.headtemperature)

OPERATIONAL VALTJES:
normal: 180-220oC (355-430oF)
mzx.: 25OoC (480oF)
difference
b€tween 2 cyl. 20oC ( 36'D

ECT: (exhaustgastemperature)

normal: 460-580 oC (860-1080

oF)
max.: 650 oC (1200oF)
difference
betwcen2 cyl. 2soc ( 45oF)
crankcase temp.max.: 80oC (175oD

IGNTNONSYSTEM: breakerlessDUCATI capacitordischargedual ignition with

dagneto genemtor.

IOMTIONTIMING: 1,47mm = .059in. (16 o) BmC

PICKI'P CAP; 0,45+ 0,55mm (.018+ .022in.)

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 GENERATOR OUTPUT: 170WAC at 6000l/min and13,5V RMS

RECTIFIER- REGULATOR a) 866 080,equires minimum load 12W (lA) to regulare.

(optinal):
b) 264 870, no minimum load required.

SPARK PLUG: 14mm B8ES

ELECTRODE GAP: 0,4+ 0,5 mm (.016+ .02in.)

CARBURETOR: I x Bing 36 mm (1,42in.),handor cablechoke

2 x Bing 36 n\n (1,42in.), handor cablechoke

FUEL PUMP: singlecarb.: pneumaticfuel pumpDF 44

dualcarb.: pneumatictuel pumpDF 52

LUBRICATION OF 2-strokeoil (for highperformance

air cooled2-cycleengincs,
ENCINE: proposedASTWCEC standardTSC3) for instance: Castol
TTS or Blizzad oil

MDCNG RATIO: 2 70oil (1 partoil with 50 pansfuel)

STARTER: rewind staiter

optional:
a) Rewind stanerv/ith electric stane!, p.t.o. side (for
enginewithout reductiongear-box) or

b) Electric starter,magnetoside,without rewindstarter

(gear-boxis possible)

REDUCTION GEAR.BOX, rcductiongear-boxwith torsionalshockabsolbe!,maxpropel-

TYPE "B" (optional): ler inenia3.000kg cm2
ratiosavailable:i = 2,0/ 2,24| 2,58

REDUCTION GEAR-BOX, reductiongear-boxwith torsionalshockabsorber,for plopellgr

TYPE "C" (optional): inertia up to 6.000kg cm'?
mtios available: i = 2,62I 3,ffi | 3,4'1/ 4,ffi

LUBRICATION OF GEAR- gearoil API-GLSorGL6,SAE l40EPor 85W-l40EP, astem-

BOX: peratr-Ilerequires.

DIRECTION OF ROTATION: view on p.t.o.crankshaft

end: counterclockwise
reductiongearbox shaft: clockwise

to ordersuitableprcpellerfor enginewith reductiongear

on Eactorapplication: specifyleft-handpropeller

on pusherapplication: specifyright-handFopeuer

COOLING: air cooledby axial fan, or fr€c air for specialapplications

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 ENGINEWEIGITTS: inoke silencer,fuel puop,
withoutcarburetor,
exhaustsystcm, kg (67,01b.)
......30,4

ADDMONAL WEIGHTS: carburetorwith rubbersocket

kg ( 2,0lb.)
andclaurps:.,..,..,...,..................,,.................0,9
Exhaust systern kg (10,81b.)
assy.4pro'x..,..........,,.,.....4,9
kg ( ,61b.)
2 airfiltcrs..................................................0,3
kg ( 1,1lb).
I doubleair fiIter.........................,...,.,....-...0,5
Inake silencerwith filtcr, fcll singlcca$. .0,Ekg ( 1,81b.)
Intakesilencarwith filter, fo! dualcarb.....1,1kg ( 2,4tb.)
Elcctticstartcrkit, p.Lo.side......................3,4
kg ( 7,slb.)
ElecEicstarter kir, magneto kg ( 7,7lb.)
sid€................3,5
Reduction gcar-box kg ( e,9lb.)
"B", dry......................45
Reduction gear-box kg (17,61b.)
"C",dry..................-...E,0

I
.

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 18) Main torquing specifications:

Nm in.lb.
1) Cra kcase
screws .M8............................-....-.--....-....22
195
2) Gar <case ruts(orsctervs).........,..
base M10.....................................,.,....38
335
base
3) Oankcase studs
.............................M10
..........................-.................
12 105
4) Cylinder
studs... ...M8.....,...........................,............
7 60
headnuts.................................M8
5) Cylinder ....................................,.........22
195
6) Allenscrewsforstatorplate..................M5.........-.-.-..--.......................7
60
7) Taptite forpickup......................M5
screws ...............................-..............
6 55
housingnut...-..-.....-.-..-.-..M22
8) Magncto x 1.,5
-....--..-.........................90
800
9) Fanhousing .......................M6
allenscrews ..............................................
10 90
10)Fannut............... ..MI6x 1,5...................................60
530
pulley......,.....,M8
for starting
I l) Allenscrews ...........................
..--....-..-.......22
195 I
12)Eex.s6ewsforrcwfuid
starter...............
M6 ...........--.-.-.-.-...................10
90
13)Hex.sclews
fo! cylinder
cowling
..........
M8 ....,.....,.,................,,,...........,..
14 125
manifold
14)Intake sqews...................,,.....M8
.,...,................,....-.....--...........22
195
15)Intake
manifold ..........................M6
screws ...........-..--..--.....................10
90
16)Spa*plugs14(coldengine).................M14x1.5.....................................n
240
17)H€x.screw coilplate...........M6
forignition ..............'...............................
5 45
18)LocknutsforeIectronicbox.,...,,....,,.....M6.........................,,...................8
70
l9) Hex.scTews gear...................M8
forstarter .......,.-..--..-.-...,,..,,.,.,,........22
195
20)Locknusforclectric
starter..................M8
..........................
-...................22
t95
for&ivegear.-..---.-.---.12-20UNF................................60
21)Hex.screw 530
22)Sftdfor gearbox .M8..............................................
8 70
forgearbox
23)Hex,nuts/ screws ..............M8
.,.......-..-....-..-.......,..,,...,,,...24
210 I
SUBJTCTTO MODIFICATIONWTITIOUTNOTICE.

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 oi
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atct i%**j?*{:6'= J

s\gl,
$ts
rFc
s**
iFc
. tFo !ro.
sv*
aFo

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rFo'

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s* +o s* +o

. s"Fsi
"

ffiffiil#'-,'trr,ffi@
F:rqgd HRirAXl

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