ALL ROTAX TWO STROKE ENGINES CRANKSHAFT FAILURES, PISTON SEIZURES
(A) INTRODUCTION THIS INFORMATION IS INTENDED TO ASSIST THE AIRCRAFT DESIGNER, MANUFACTURER AND BUILDER TO ACHIEVE CORRECT OPERATING CONDITIONS AND ASSEMBLY FOR THE ENGINE AND CONSEQUENTLY OPTIMUM PERFORMANCE AND RELIABILITY. (6) TECHNICAL DATA AND GENERAL INFORMATION IN ADDITION TO THIS TECHNICAL REFERENCE PLEASE REFER TO: - CURRENT ISSUE OF OPERATORS MANUAL - ENGINE DATA SHEET - POWER, TORQUE AND FUEL CONSUMPTION CURVES - CURRENT ISSUE OF SPARE PARTS LIST - ENGINE INSTALLATION CHECK LIST -ALL SERVICE INFORMATION BULLETINS REGARDING YOUR ENGINE
FIELD REPORTS HAVE INDICATED THAT SOME ROTAX ENGINES MAY BE SUSCEPTIBLE TO CRANKSHAFT FAILURE OR PISTON SEIZURE DUE TO THE USERS FAILURE TO CONDUCT PREVENTIVE MAINTENANCE AND MAINTAIN A CORRECT OPERATIONAL ENVIRONMENT. ROTAX HAS DISCOVERED THAT CERTAIN OPERATIONS PERTAINING TO THE FOLLOWING ITEMS INDIVIDUALLY OR IN CONJUNCTION WITH EACH OTHER CAN CONTRIBUTE TO THE ABOVE LISTED PROBLEMS:
(1)
PROP LOADING AND INERTIA FACTORS AS WELL AS PROP BALANCE. SEE SERVICE INFO “3 UL 89E” AND “4 UL 87-E” PARAGRAPH 2.2,ALSO INFORMATION “9 UL 91-E” PARAGRAPH 4.4, 4.5, 4.6.
(2)
FUEL PHYSICAL AND CHEMICAL PROPERTIES, AS WELL AS IMPURITY. SEE KODIAK SERVICE INFORMATION “USING AUTO FUEL IN YOUR ROTAX”.
(3)
FUEL AGE AND STORAGE PRACTICES. SEE KODIAK SERVICE INFORMATION “USING AUTO FUEL IN YOUR ROTAX”
(4)
FUEL DEUVERY/PRESSURES SEE SERVICE INFORMATION
(5)
CARBURE-ITOR JET-I-ING AND CAUBRATION. SEE SERVICE INFORMATION “8 UL 87 E”, AND “7 UL 87-E”.
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AS WELL AS CARB VENTING. “9 UL 91-E” PARAGRAPHS 6.1, 6.2.
SERVICE
(PAGE TWO) (6)
AIR FILTER TYPE AND SERVICING. SEE APPROPRIATE OWNER AND PARTS MANUALS FOR YOUR ENGINE. FOLLOW K&N CLEANING INSTRUCTIONS AND USE CORRECT FILTER OIL. ALWAYS REPLACE ALL WORN PARTS WITH ORIGINAL EQUIPMENT PARTS.
(7)
OIL ANTI-WEAR/ANTI CORROSION/ANTI-CARBON ABILITIES. OIL MUST MEET MINIMUM REQUIREMENTS OF “ASTM/CEC STANDARD, API-TC CLASSIFICATION”, WITH A POUR POINT AT LEAST 10 C BELOW THE LOWEST OPERATING TEMPERATURE. ONLY HIGH QUALITY OIL SHOULD BE USED.
(8)
AIR FRAME DESIGN RELATIVE TO ENGINE COOLING AND AIR FLOW. SEE SERVICE INFORMATION “9 UL 91-E” SECTION 5.
(9)
NON APPROVED/INADEQUATE SEE SERVICE INFORMATION
(10)
INADEQUATE WARMING-UP OF ENGINE. PU’lTlNG A COLD ENGINE TO HARD WORK WITHOUT UNIFORM AND CORRECT WARM UP WILL CAUSE THE PISTONS TO EXPAND QUICKER THAN THE CYLINDER, MINIMIZING CLEARANCES AND CREATING PISTON SCUFFING AND SEIZURE.
(11)
ENGINE MOUNT DESIGN AND VIBRATION/HARMONICS ISOLATION. POOR ENGINE MOUNT DESIGNS WILL NOT ISOLATE VIBRATION ADEQUATELY AND CAUSE PREMATURE ENGINE WEAR AND DAMAGE. TWO STROKE ENGINE INSTALLATION CHECK LIST”.
ENGINE COOUNG SYSTEMS. “9 UL 91-E”, SECTION 5.
AND HARMONICS ALSO SEE “ROTAX
(12)
ACCURATE CAUBRATED ENGINE MONITORING REGARDING RPM, EGT, CHT AND UQUID TEMP. SEE SERVICE INFORMATION “6 UL 87-E”, ALSO SEE ROTAX FLYDAT.
(13)
EXHAUST SYSTEM MODIFICATION AND OR LEAKAGE. SEE SERVICE INFORMATION “9 UL 91-E”, SECTION 8, AND “11 UL 87-E”.
(14)
INCORRECT STORAGE PROCEDURES FOR THE PREVENTION OF CORROSION. SEE APPROPRIATE SECTION ON CORRECT STORAGE IN YOUR OWNERS MANUAL.
(15)
INADEQUATE OR INCORRECT ROUTINE SERVICING. SEE APPROPRIATE SECTION ON MAINTENANCE IN CURRENT OPERATOR’S MANUAL AND SERVICE INFORMATION 3UL91E.
(16)
ISSUE OF YOUR ROTAX
IMPROPER PRE-FUGHT CHECK_ SEEAPPROPRlATESECTlONON”PRE-FLIGHTCHECK”INCURRENTlSSUEOFYOURROTAX OPERATOR’S MANUAL AND SERVICE INFORMATION “3 UL 91-E”.
WE RECOMMEND ALLOWNER/OPERATORS EDUCATETHEMSELVES ON EACH TOPIC AS LISTED, AND REFER TO THE APPROPRIATE DOCUMENT PRINTED BY ROTAX ON THE SUBJECT AS WELL AS ANY ADDITIONAL INFORMATION AVAIlABLE AND APPROPRIATE. IMPORTANT1 STRICT ADHERENCE TO THE nROTAX TWO STROKE ENGINE INSTALlATION CHECKLIST” MUST BE FOLLOWED. IF YOUR ENGINE INSTALLATION HAS NEVER BEEN CHECKED AGAINST THE ¤INSTA~ATION CHECK usr, ~0 so NOW. THIS LIST CONTAINS CRUCIAL INFORMATION THAT DIRECTLY APPLIES TO YOUR ENGINE, AND IS AN EXCELLENT TOOL FOR FINDING POTENTIAL PROBLEMS. DANGER! FAILURE
TO COMPLY WITH THIS RECOMMENDATION COULD ENGINE DAMAGE AND PERSONAL INJURY1
Special attention should be given to the changes which have affected prop hub bolt pattern and centering collar (see sketch 1 page 4). (A) INTRODUCTION.
Identifies an instruction, which if not followed, may cause serious zungen oder Lebensgefahr fur den Befreiber oder andere, drilfe injury or even death. Personen ...
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Cure: Use an aerial cable with double screening! In special cases, an absorber cable (â100 Hz aerial connecting cable), order number 29210 435 0100, may.
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The cylinder head, as well as the complete intake and exhaust systems are new. TH- .... o The additional emission components which are required result in increased manufacturing costs. ... exhaust manifold on the right side of the engine.
more time looking outside the cockpit and less time looking down at the screen. ... 'Procedure' button which makes it easier to load approach, departure (DP) ...
intake manifold vacuum and signals the PAIR solenoid valve. The manifold vacuum is applied to the PAIR control valve and ... specified by the manufacturer. 1-7 ...
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Refer to the spark plug manufacturer's data for spark plug servicing information and required specialized tools. Spark plugs must be removed, cleaned, ...
