rotax two stroke rebuilds

[Guest Guest]

hi all

 

could someone enlighten me as to what a zero hour rebuild on a rotax two stroke actually incorporates ?

 

does a top rebuild qualify or is it also necessary too rebuild the bottom end

 

It seems to me that there is no set crteria,

 

Life is mostly froth and bubble

 

two things stand like stone

 

kindness in anothers trouble

 

and courage in your own.

 

not mine percy

 

 

[Guest TOSGcentral]

I have done a few of these (the last one was last week).

 

There are a number of factors involved that you need to understand.

 

A basic ‘zero hour’ rebuild will be a TOTAL strip of the motor and basic shell components thoroughly cleaned and inspected.

 

For a ‘zero hour’ you will get new pistons, rings, what few gaskets

 

there are, con rods, gudgeon pins/bearings, new heavy duty crank, new

 

main bearings and con rod bearings.

 

This should normally include benching the stator and checking that out

 

fully. You will usually find that you end up with new HT

 

leads/caps/plugs as well.

 

If in the hands of a responsible person then you will get a zero hour engine back that you can rely on.

 

But there are of course peripherals! Cooling system (532 & 582),

 

Reduction gear boxes, and starter motor. These are NOT part of ‘zero

 

hour’ engine but are best done at the same time. They can all be

 

checked and measured with corrections as needed.

 

You should note that this process is expensive – mainly in parts. It

 

would appear that Rotax got pissed off with an enduring poor reputation

 

and stopped supplying component parts. Many of these require specialist

 

tooling and presses. A few back yarders thought they knew better and

 

the failures continued unnecessarily.

 

So, for example, you cannot rebuild a crank yourself – you get an

 

entire new assembly with rods already attached etc which can then be

 

put in the crankcase.

 

To dissuade you further – over the last few years prices have escalated

 

something fierce along with the excision of all but one Rotax agent –

 

Bert Flood. The situation has nearly got to the point where it is

 

nearly as cheap to buy a new basic motor than zero hour an existing

 

one. I can see Rotax’s point but it was only a few years ago I was

 

looking at about $2500 for a good rebuild and now it could be up to

 

$3500 or more! Bit sad but there you go.

 

I get all my engines done by Richard Eacott at Boonah (who has been through the Rotax factory courses in Austria)

 

and stays bang up to date. He will also give you a wealth of advice to

 

steer you in the direction you should go including fault finding.

 

Absolutely no bullsh*t from Richard! You can get him on 07 5463 2476

 

Aye

 

Tony

 

 

[Guest micgrace]

Hi tony,

 

I believeit was possibleto obtain a rebuilt crankshaft for 503/582 at one time.

 

I can't recall of it being mentioned nowdays. Anyone have any info?

 

Micgrace.

 

 

[Guest TOSGcentral]

Yes you can get the cranks - but they now come as complete, assembled

 

sets - you cannot get the bits and put them together yourself because

 

they have to go in special presses and that is what Rotax apparently

 

kicked up about!

 

I do not know of 're-built cranks' - never heard of them, so I would suspect not!

 

You can still get the separte bits to do a top end overhaul yourself -

 

pistons, rings, gudgeon pins, bearings etc, plus re-hone the bores

 

yourself.

 

T.

 

 

[Guest micgrace]

Hi Tony.

 

I have actually seen a professionally rebuilt crankshaft. I couldn't recall who did it. Should have taken some notes.

 

Micgrace

 

 

[Guest micgrace]

Hi again.

 

I checked out the rotax parts catalogue. You are right. No overhaul parts available for crankshaft. Such a pity.

 

Which means whoever was selling reconditioned crankshafts would no longer be doing it.

 

I notice only 2 rebores available as well. depending on condition, probably effectively one only

 

I

 

would almost be tempted to obtain a new engine each time, rather than a

 

rebuild under these conditions. I don't think there are much savings to

 

be had, especially as all ancillary equipment would need overhaul at

 

same time.

 

For those who are interested in the current parts catalogue, the link is

 

http://www.rotax-aircraft-engines.com/pdf/dokus/d01371.pdf

 

It's nearly 400 page file, so forget it without broadband. It's in German/English

 

Micgrace