Rotax 277 Operator's Manual

I

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OPERATOR'S MANUA L

TYPE 277

ENGINES

EQUIPPED

W

ITH

BOSCH

CONTACT

BREAKER

IGNITION

SYSTEM AND

BING

CARBURETOR

Edition:

O3 1988

,l

THIS

I{ANUAL

CONTAINS

IMPORTANT

SAFETI

INFoRI1ATION

CONCERIIING

YoUR

ENGINE.

WITH

THN

EIIGINE

AT TIME

OF

RESALE.

AND MAINTENANCE

IT SHOULD

REMAIN

t

I

SECTION

1. SAFETY
Inportant

Preface,

Genenal

Safety Points

FOREWORD

FUEL I4IXTURE

Fuel & Oil, Mixing

procedure

STARTING PROCEDURE

Pre-start check,

procedures

.

. .

BREA(-TN PROCEDURE

CARBURETION

INDEX

EXHAUST

SYSTEiIS

....,

INSTRUMENTS-HO}T&WHY

PAGE

a

a

f

4.

r

2

4

5

7.

8.

Carburetor, typical

description

6
I

I

ICNITION

SYSTEI.I

Ignition,

Timing

procedure

9

SPECIAL

OPERATION

CONDITIONS

FLoat

flying,

Alr

systens, Noise reduclion

,

L2

MAINTENANCE

SCAEDULE

Posb

Break-in inspection,

Spark

plugs,

rewlnd starter, cooling,

engine

tining,

carburetor aqjustnent,

engine head

torque,

engine nount cheqk,

air

and

fuel filtration,

decarbonizing,

storage

......

l,

TROUBLE SHOOTJ}IG

18

SNGINE

REPATR

LOO

,........

79

LIOHI'INO CIRCUIT

2T

WIRINO DIAGRAI1

..,...

24

TECHTIICAL DATA

...,..25

customers'

Infonnation

26

.i i

,ii

'i

10.

11.

14,

rt.

16,

I

{,

f

SECTION 1

a

-

Never run Ene

englne on

turning

unless

you

are doing so

anyone or

anything

entering the

safe

place

is a detinite assel.

,al

-

Never

leave

your

aircraft or other

vehicfe

unattended

whiLe

the engine

is

running. If operated

by soneone else

you

could be

sued even if the use was

unauthorized by

yoL,

|

-

X""p an engine log

and. enter any unusual operation. Do

nob fLy unless

you

ltave corrected

the

problem

ancl

recorded

the

correction

in !he toa,

I

I

IMPORTAi{T

PREFACE

Safety

is everyone's business, l,le have

included sone of the

inportanb safety tips here, but the

list is not

complete.

It would

be

impossible to list every lray in which one

nay

be

injured. We

would rather risk

your

indignation

by

mentioning

that

I'trhich

every-

one knows is dangerousri than take

the chance that needless injury

could occur,

Pfease

note the following

synbofs

throughout the book:

A

-

Safety i,y'arning: Failure

to obey a safety warning may

result in injury

to

you

or

others.

I

-

Intor.ation vltal to the operation or

nalntenance of

your

product

(in

aircpaft this should

also be considered

necessary for

safely ) .

GEJ.JERAL

SAFETY POI}ITS

A

-

t't.,r""

mix fuel in an

area that ls enclosed or vhere

furoes

could

reach an ignition

point.

I

-

:'take

sure all

engine

controls

are operative,

thab

you

know on and off

posilrions

of

throttfe

and

ignition,

that they

are. easily accessible,

and

that

you

can operalte

then inslinctively

without

hes itat ion.

,l

-

Never

refuel

an

aircraft

if fuet could be spilted on

hot

engine conponents. Use

safety approved.

fuel

containers and

never

transport fuel

in an unsafe

manner.

l

-

Check

engine

mounting

system frequently

as well as the

drive components, fuel

lines,

wiring,

and fue-l and air fllters,

,ll

-

Check for luef conltamination,

air vents,

etc.

Protect

engine

while not in use fron any

contamination

entering

exhaust,

fuel,

or carburetion

systen but be sure

to

renove storage

protec-

tion

before

sbarting engine,

|

-

t'taintain

your

engine in top condition and

assurne

it's

going

to

quit

running

at any tine. Leave

yourself

an out in the

evenb of

unexpected

failure.

the

ground

r"rith

the

propeller

in a run-up area and

can

observe

danger

area. An

observer

in a

I

I

SECTIOi'I

FOREI.'ORD

Ihe

ROTAX engine

is

an

air-coofed 2 stroke

engine,

care-

ful and extensively

tesbed design and ruBBed construction

aa

well

as the

use of high

qualj.ty

parts

warrant

maxinum relia-

bilj.ty

and durabifity. With

proper

naintenance and care and

wilh the

use

of

suitabLe

fuel

and

oil the engine will

give

you

trouble-free service for many

yearg.

The ROIAX design

incorporates

the

latest

technical developnents. In order to

take

advanta8e

of luture developments

we reserve

the

right

to

make nodifications

in

the

RotAX

design r,rithout notice.

I

ilote

all

fastenera

are nebriq with the exception of the

internal thread

of

the

P.T.O,

shaft which is 1/2" national

fine thread.

It is to

your

advantage

to

read this ranual carefully

for the

protection

of

you.rengine.

There

may

be extrene

differences from other types of two cycle engines

you

nay

e worked on.

Always

use

genuj"ne

RoTAX

parts.

Never

run engine wj.thout

proper

loading, e.g.

propeLler.

SEC'T ION

FUEL AND OIL

Fuel

conlraminati.on is a major cause of engine

failure.

The

best

place

to avoid contanination Is at the

source, once

in

your

fuel container,

a very harzadous

potential

exists.

Use

a clean safety approved storage container.

Filter

alL fuel entering

and leaving this

container. Do

not

over-fiLl

container, al1ow for

expans ion.

/l

IIARNIN0:

oasoline is flarunable and explosive under

serlain

conditions. ALr{ays

perforn procedures

in a

well

venti-

laled

area. Do not

amoke

or

al-low

open flahes or

sparks in lhe

iniry. Never add fuel while

engine

is running,

Refer

to technical data. The engine

is

designed to

operate

at a

fuel rnix

ratio of

50

to 1, De sure

to use

products

of, at

least the

standard shown ln

the technical data section.

0

hav

I
I

v1c

r

-

)-

If the engine is

to

be used

inverted

(with

spark

plugs

pointing

down)

select

a lubricant which

features

1ow carbon

deposits,

OiL residue

tends

to drain

to Lolr

points,

i.e,

6park

plug

cavities. If this resialue

fails

to burn clean

during

nornal operation,

plug

fouling will

occur,

possible

pre-ignition

also.

I4anufactures

of

suitabfe

lubricants

will

guarantee

their

products

in writing.

I4IXINC

TROCEDURE

STEP

no.1:

Using a clean approved
container of known

volume

fi.11 correct

amount of

i.nto container,

Oi1 must be approved for

cooled engines at

50

:

1

ratios.

STEP

no.2 iAdd fuel to obtain desired

mixture

ratio

(water

nesh

fi.lter).

I

FueI nusl

be mininum

l,l.O.i.l. B, or R,O.N.

90

ocbane

rating.

Replace container

cap and ahake

the container.

Thoroughly

agitate the sonbainer.

Then

using a funnel

vribh a

fine

roeah

screen

!o

prevent the

entry

of

witter and

forej.En

particles,

transfer

mi

x ture

fron

container into

the

fuel

tanK,

o 1_L

air

ntx

STEP

no.

l:

:=

a

=:

-e

-a

-q-

SECTION

4

STARTING

PROCEDURE

PRE-START

CHECK

Before

starting

engine

read

seclrion dealing

with

starting

c

and

engine

break-in

thoroughly, The

service life of bhe engine

is largely

deternined

by

how welL

you

foLlow

these insbructiona.

A

Before

starting

engine be sure

your

installation is

conplete,

secure and all

contnols operate

easily and smoothly,

that

you

can operabe them instinctively.

A.Iways ensure that

you

are in a safe run-up area,

Ensure

throttle linkage allows

piston

valve

in carb

to

bottom

in i.dle

position,

Screw out idle

speed adjustnent screw

(no,lo,

pageT)

until

carb

piston

(no.J

)

bottoms. Carefully turn

in

adjustment screw until it engages

piston

and

turn in a

further

t + 3

1,/2 full turns.
Check fuel line is

connected

and tank vent

i6

oDen.

PROCEDURE

On

cold engine apply choke

ful1y.

Leave throttle a! idfe

and

A

I

position.

Opening

throttle

wi.Ll

greatly

reduce

choke effect

resulting in hard starting. l4ake sure

ignition switch

is on and

-

you

can shut

ii off i.nstantly if necessary.

Pull sbarber

until

firnly engaged and then

puI1

smartly through,

Above

procedure

should be repeated unti.1 engine

begins

to

"fire".

As soon

as engine starts, advance the throttle slowly to

Low speed and remove choke as

soon

as

possible,

ProLonged

use

of

choke can cause

engine to flooal.

If the engine fails to

atant

or operates only on one

cylinder, check vrhether

the ignition wiring is

dj.sconnected

from

lhe spark

plug protectors

or

fron

the spark

plugs.

Ensure shorting

switch is in

correct

position

and nired

correctly.

If

preceeding

checks

do not

correct the

proble!n,

renove

the

spark

plugs

and inspect.

Wet spark

plugs

denote flooded

engine. Replace with dry

plugs

and renove choke.

t

Dry rprrk

pLugs

indica!e

no

fuel

in

engine. fnspect tank

fuel Leve1, fuel valve and

lank

vent, Renove

float bor'/1 and

ensure fue I is

preient.

SECTION

5

-5-

BREAK-

IN PROCEDURE

for aircraft

inst

al lation

(in

obher applicalrions

proceed

accordingly)

The

break-in has to be

performed

with the

engine installed,

properly

loaded.

In case of

an

aircrafb, anchor

the

plane

to

the

ground.

Run

the

engine

according to the

follolring

graph:

FUU

5

q

t

2

0

10

15

20

f0

10 6o

50

lt0

l0

20

111111

11

2

I

Be sure to

use a

safe

run-up

area, to anchor

aircraft at

those

points

approved by the

airfrane nanufaclrurer,

and to have

someone

present

lrho is

able to shut off

the engine instantty,

I

Attu. this

procedure

the

idle has to be adjusted. Then

short

take-offs

can be conducted. After

a few short full-load take-offs,

but

not later than 2 hours total

running time, the cyfinder

head

nuts

have to be

pe-torqued

to

19:2q Nm

(160

i

210 in.lb.).

For

this

prosedure

the cylinder cowl

(if

any) has to be taken off,

F.nriha h[<t ha.^ld f^F ra-t^r^,,ih' ^f har.l

Tools:

Screwdriver, insert 1l

(socket

l'rensh 1J),

torque wrench.

Note:

Use a cro6s sequence for tightening

the nuts.

Consider both heads as one unib

because they are

joined

by

exhaust

and rnanifolds.

Ensure that

cowl bolts are torqued less than head bolts.

IUnition

point

rubbing blocks

wear

rapidly

durjng

the first

hours

of operation lil1 they

I'potish

in'r on the cam

of crankshafi, therefore

bhe

poiots gap

may

require

adjustment after breal(-in

(betw.

8.10 hrs)

I

nufu" to ignition biming

procedure.

After

inibial break-in

adjust-

ment

1s

perforrned,

only

normal nainltenance

is required

(see

maintenalrce

scheduLe ) .

-6-

SECTION 6

CARBUNNTfON

The BIUG

carburetor

is a

piston

type

carburetor

with

float

chamber.

-lhe

carbJretor

can be

adjusted oy

jet

replace-

ment

ofvarious approved

sizes,

by

adjusting

idle airlfuel

mixture

screw, carb

pision

stop adjustr0ent,

needle sjrzes,

and needfe

clip

posirjo.l,

'fhe

a-irlfuet mixLLrre

at idle

speed

is

adjusted by the

air adjusting

screw

(see

ill.

no.

28).

The idle

r.p.m. is

adjusted by the

carburetor

piston

adjust-

ment

screw

(i11.

no.

JO)"

llote

-

theae idle

adjustnents

interact, so

adjusting one may

require nlinor

adjustment of

the other.

must be

in

p.lace

for

proper

carburetion.

See

section on

speciaL operating

conditions.

r,--

"-

-,,---d be

done only afber

al1 other

iteros have

been checked,

and tllen by an

e{perlenced

two-cycle

nechanic.

A Ensure

that throttle

qabfe

and finkage

do not

sticl( and

that carb

piston

valve

can be opened fuLly

and cfosed

to

the

point

where

the

piston

adjustnent

screr no.

JO

corltrols

piston

opening

and idle Rfl'l. t{inor

adjusbments can

be

made

ab cable

adjustment screw

and lock

no. 12 and

no, 11,

Air intake filtration

and

noise reduction

devices

tse certain

that throtile

linkage is

not affected

by

engine or

airfrane novelnent.

This could

change throttle

se tt ings

.

Special

operating

conditionsr

suctl as severe clirnate

or altitude

change nay

require

different

jetting.

Contact

your

dealer.

-7-

BINC CARBURETOR

-

TYPICAL DESCRIPTION

vindo, at carburetor

piston

rru L

d

P4r

,3,{

.^E

''

l ll- ro

11-6

',r

-

/.".>-

|

-,'ls

fr. e

33

Etecqtion:

Hith

(Note:

this

is

13

16

)

,/\

,-::\

-24

29

39

I

,L

\.?

n

­1-l

u

3

1

+11

i135

Vao

E34
P.

37

fl.

BING-double

float
carburetor
carburetor

hqusing

carburetor

pis

t on

j

et

nee d 1e

h^l di ho n1atF

plastic

spring cup

spring
cover p late

he x, s-crew
nex. nul

adj

us tment s crew

idler

jet

needlo

job

mixinB tube

float needle

valve

cIj.p

float
float bracket

pin,

float

gasKe

I

float

charnbe

r

O-

rin

g

eir rofl,taiina

q.rFU

spring'

adjustment

b-.0

50

venL line

starti-ng

piston

with

gas

Ke r

s lee ve

oPr 4,,ts,

r !4r L!16

plston
c fosure

s crew

starting

piston

with

gasKeE

oyr :r,E, J uar urIB

piston

c fosure

Screw

Iubber cap
chol(e lever

as Ey.

hex, nut

lock washer

5

cyI, s crew

MI(UNI-fue1 pump

&! 6y

ao---6\n-

f\l

ll41
142

43

t7-

3 A

^

-19

te-E

-J,-zo

21

1)

)!

<3

re

U*

37)
JB)

19)
qo)

lr1)

n)t

4rr)

11)

34

)

t)t
)a)

2

t

4
5

6
7

8

-9
10

11

7t
14

18
20

2I
22

2\

27

s

ctew

J0)

adjustment

screlr

4s!

q

gN

n-/rl

"/

|

qP@

r,'

I l-3

'tt

SECTION

7

EXIIAUST

SISTEITS

Considerable effort has

gone

into the

desi8n of

the

ROTAX exhaust

aystens.

Any chan8es may severefy deteriorabe

perforrnance,

reliability, engine 1ife,

fuel

econolny,

and tlre

systen-s abil"ity to reduce noise to acceptabfe level-s.

neware

of any accesso!'y systens that advertise an inprovenent

over

the

6tock components.

I

Vibration

due to inproper

nounting is any

exhaust

system's

worst

eneny,

Pnoperl"y mounted and

maintained, your

exhaust system will

provide

a

long

service fife, Never

renove

coupling spring with

a sharp

object or one which

can nark the

spring

naterial,

A rounded screw-driver 6hank or a hook

fashioned

fron 1/Il'r

ban stock is ideaL. Safety-wiring of

springs

is highly

lecorunenaled.

SECTION

8

INSTRUI'IEI'ITS

-

HoW

AND

WHY

Instrunents

can

be

a valuabl.e addition

if

they are of

good quality,

correctly instalLed, are tronitored, and the

igni.tion systen.

Alternativefy

use a tachometer

operating

on

the

lighting coiL.

All instruroents requiring

power

source nust be overload

,

...

protected.

All niring and sensor

leads

nust

be

properfy

routed,

protected

from vibrations

and abrasion

The

277 engine

is

designed

and

tuned to operate

at

6A50 +

6500 r.p,m.,

ful1

1oad,

ful1

rrottte.

operator understands what they

are

te1llng him.

A

Never

use a tachorDeter wtrish

can

cause

a short-cut

on the

-9-

SECTION

9

IGNITION SYSTEM

the ROTAX engine is equipped witlr a BOSCH

magneto

generator

ot 12V

75/2JW

rating,

producing

the current necessary for the

spark and

accessories. The

igniLion

un.it has been seb to

precise

tolerances by

the factory. After

initial

break-in

adjustnents make

no

changes

unLess

absolutely

necessary.

fn case of trouble observe the following

I

If bhe icnition

tails

interuittently or if there are

other

troubles

that are due to

neither spark

pLug,

nor external"
components, nor carburetor, the contact breakers nay be the
cause. Contacts must be clean

and

must

not be

burnt. i,,lith

ner{

entines or nel.r

points

bhe can-fol-lorrer of

the

ignition

point

set wears rapidly initially. llesetting of contacts rnay

there-

lore

be necessary al'ter some time.

The

breaker contacts

are

accessibLe after renoval of the renind starter

and the startinB

pulley.

The magneto

housing need not be renoved. onqe

cam

follower has

"polished

in" and

points

are

re-adjusted,

sebtin8s

will trold Ior considerable

time. lo check whether

the ignition
tiriing :is correct,

btrere is

an arrow

on the fan

lrousing

ehictl

corresponals to

a fan bfade with

a

cast inarker

as indicated.

fan

l')ousing

nark

I

I

fan blade mark

-10

-

+ihih^ f^E i--l+i^-

If adjustnent is

necessary

alignment

marks once

the recoil

f <Fp il l',qtFqtsi^nl

l'he

I'iring

poinb

for

ttri8

engine

ston movenent

resp.

1B + 20o

B.T.D.C.

is .08

+

.1r' B.'t,lJ.C,

crankshaft

movenent.

At

the

point

of

alignment

this indicates the

correct

there is a further

set

of

starter nechanisn

is removed

T

pi

r.q!'llTI9X

TIMING

(

procedure

)

1) Disconnect

spark

plug

wire and remove

plug.

2) Remove

engine cooling

slrroud

and recoil

starter

housing.

3)

Rotate

crankshaft untit

breaker

points (visible

througb

magneto

rin8) are ful1y

oper!.

Adjust

point gap

to

.072

ta .O75 inch

using

a feeLer

6auge

and screw

driver

as illustrated,

IIOTE: Breaker point

gap

can

change upon

tightenang,

Always

recheck

after tighten-inE,

4)

Disconnect

the rtouble

lead

wire

from the ignition

coit.

conneqt

one

end of a

tining

light

(flastrlight

type)

or a tone

timer

to

the double

lead i\'ire

connection

frorn

the engine.

5)

Turn timing instrunent on.

Rotate crankshaft until

piston

JJ,I,IJ Ilg

illill t!s dr. i

rrrt,

.tlle

L1m1ng

II

-r5'rer

YorJ

ture

plate

retainlng

screws and

tining fluctuation a1ign, then

Insure that

ignition switch is on.

approaches top dead

centre and

light should fluctuate or tone

not, then

sfacken

the three

arma-

rotate the

plate

ti1l nlarks

and

retighten retaining

screws.

loo early

r

turn

arnature

plate

c 1o clo,ri s e

1I0?E: Timing may change upon tightening

screids, Recheck anal

correct

as necessarv.

Too late:

turn arl:lature

plate

count

er- clo

chwi s e

6) lJhen correct tining

is achieved,

ar'{ay

gap.

The

gap

rnust

be within B

(see

illustration) when the rnark on

mArl. ^h f.n h^rrqi hr

If

the

break-ar{ay

gap

is out of

may have

turned

on

the

crankshaft,

.tecessary,

check

pole

shoe

break-

to

17

nm or

0,J

to

0.67

irr.

ffywheel corresponds

vrith

f^l6r.n.a flr6 fI u h6ol

Remove

flywheel alrd inspect

magnet

1)

once conpleted,

reconnect

all wires,

and

cooling

shroud.

aoj

{s"

"age

\./4

)<

shoe

cardboard

striP

rep-lace

recoif

s tart

er

-72-

SECTION 10

SPICIAL

OPERATII{G COIJDITIOI{S

Float

flying

off water is a

real

pleasant

experience

-

usually. However, there

are dangers to

your

engine

you

won't

experience

on land.

Some of these dangers are water ingestion

on

take-off

or landing due to spray

and

splash,

conosion,

electrolysis,

and worst of a1l unintenlional aubner:sion.

The hi6h

carbon

content of high

quality

bearings,

crankshaft ets.,

are

highly

succeptable

to

corrosion. Synthe-

tic o11s,

although

good

lubricants, often attract noisture

-.th6n l-h.h ran6l il-

I

A

good quality

air

intake systen

(i.e.

K & ll oil

inpregnated filter)

witl

prevent

most

probleDs.

Dry

e speciafly
choke the
result

i.n

fiLter elements

(paper

type)

are

not

acceptable,

in

noist conditions. They will absorb water and

engine causing over rich

carburetion mixtures

whictl

ohdi ha n^uaP I ^sq

llote: Significant

engine noiee reduction can be

obtaineil

with an air intake silencer

kit. Further:

noise reduction

may

be obtaj.ned by

the use

of an after-nuffler

kit. Be

aware lhab

modifications rnay

require

carburetor nodification. Enquire

at

your

dealer for nore infornation. Iloth are avai.lable in

the

ROTAX

parts

sy st em,

I

on

aircraft equipped nith engine

cowlings

you

nust

ensure blower inlet size is not restricted and

exit

is double

the inlet area.

There

should be no

circulation

between inlet

and exit on colrl"inB.

SECTION 11

I.{AlNTENANCE SCIIEDULE

A

ltlnltfltC

l ft is recormrended

you

have dealer

assistance

periodically

for components

or

syatens

not covered

by this

nanual,

Dlssonnect spark

plug

lead

for

all maintenance

and

inspection

procedures.

I

Service tirnes are

based on

average

use, assumi.ng

engine

is run at

least once

per

week for a normal

duty

cycle or average

flight. lotal

time before tea!'down is determined

by the frequency

and conditions of

usage, If the

engine is not

goinE

to

be used

for a

period

of 7 to 10 days

or nore, consult

storage

procedures

in this sestion,

Afber initiaf

break-in

period

certain

inspections and checks

nust be nade

to ensure all

cornponents have renained tight and

in

tolerance. Failure

to do so could lead to

premature

engine

failure.

/

POBT BREAK-IN

INSPECTION CHECK LIST

Engine tining
Spark

pLug

condition

Carburetor

adjustment

Engine

head

nuts

Engine

mounb nubs

l4uffler

a ! tachnent

Engine

coolant syslem

Air filtration

syst en

Fuel

filtration system

Electrical uiring

(loose

connections,

stripped

wires, danaged

insulation), tighten all

loose bolts,

nuts and linkage.

operatlon

of Lighting sys t em

lle

recotnfiend

ihat

you

baye

your

dealer sign

this

ingpection.

Date of Break-in insoection

narl6F o i r-rt,, F-

SPARK

PLUG

Due to varying

fuel

properties

etc,, check every

10

hours

of operation. Replace as

required

or annua1ly,

-

providing

spark

plug

heat

range

and the

carburetor

calibration is

correct, the

spark

pfug

will have a brownish

tinge at

the

electrodes.

A

sooty

spark

plug

usually indicates

a bad

pfug

or faulty ignition system i.n a sound engine.

If

the

plug

is sooty wilh

oi1

deposits,

carburation

and

air

system

slrould

be checked.

If the

plug

has

'ruhite'r

electrodes vrith

rrmeLt'r

dropl-ets,
first suspect lean nixture. If calibration is correct and
there is no

evidence

of uanifold leaks or lack of fuel, chan8e

the

plug

to a colder range. Do check if

cooling systern

ia

operating coryecbfy.

Al

Attention: Heavy oi1

deposits on the electrodes and

insulator

cause

engine troubles and have to be removed

regularly

(every

10 hours ) .

If,

after

cleaning or changing the

spark

plug, you

stiLf

have

an ignition

problen

and

no external

fault

is

found,

the

ignition

ul1it rrust be

checked.(see seclrion under ignition

syslen),

I

Never

clean 2-cycLe spark

P6h6hh6F l-^ .^116^+ l t

--

--^

^ -- -^J

gap

0,4

to 0,5 nrn or ,015 bo ,020

torqued

to 27

l,ln

or 240 in.fb,

plugs

with abrasive cleaners.

your plug

with

a wire

gauge

-

in.

Spark

pLug

nust be

cg

rem

A

REl,lItlD STARTER

Cheqk cord

condition

every

10 hours. Replace when worn

or

frayed.

1o

n.jrnr:F hrre

<fArl-n F.no f.l lnw thp h"..-drrre

Out-

lined

(the

nurnbers stated in brackebs

refer

to

the illustration)

First renove the relrind starter assembly

fron

the engine,

.jecond, remove tl'e snap

rinC

(9),

toop sprin5

(B),

circlip

(7),

pawl

]ock

(5),

and ihe

pawl

(5).

Pu1l

oub

the

starter

rope fully to the end, hold

fan

cowl

(1)

(resp.

starter housing

(1)

on free air engine

exe-

cution) and rope sheave

(l)

toBether in their

position.

There

is

an

opening in the rope sheave.

The

key clamp

(4)

visible

ih

tl'a .n-rin-

hrs

to ho rrrqha,l

^rrf

jn

tha

^nr.<iia

!ense Of

Fh- F,,rlir,..{in--.i^,, ]-,,ll t}F

-^--

n'tt ^l iha F^ne

slteave.

]'he

insert

the

nei,{ sbarter

rope into tl)e rope sheave,

moun! the

key

clamp in the sane

position

as it was before and

oun| bhe

parts

5,

5,

7,

B,

and

9.

l{arning: Do not rernove

spring

container

(2),

this

hirhi- o.'rc6 i"','ri-.

IJo noL operate

tl)c

enline if tlre rev/inJ sbarter

is

defective,

:Y:9

@

I

5

-16-

COOIII,IG

SYSTEII

(applies

to

f,an-cooled engine

version)

Inspect on an annual ba6is. Ensure no fan blade

danlage - check cowling

is nou cracked

or

broken.

Do

not

run engine with cowlings renoved.

I

Never torque cowling boLls

hagher

than head nuts.

I

@

oO
YU

@@

EiIOINE

TIi4Ii'IG

Should

be inspected

every

50

hours, Replacement is only

-

required vrhen

breaker

points

can

no

longer

be adjusted within

specifications,

.

Procedure

-

see ignition systen section.

EiiGINE

HOAD IIUTS

once

seated after

break-in inspection

they require only

annual check, For re-torquing,

see break-in

procedure,

ETiGIiJE J1OUJ'IT iiUTS

Inspect visualfy

regularly

(pre-flight

check). Re-torque

annually.

Check

procedure

with

airframe

nanufacturer,

AIR FILTMTION

SYSTEI'I

Inspecb

frequently

(10

hours) for

cleanliness dependent

on

type used

(see

special operation condibions),

FUEL FILTRATIOI{ SYSTEI4

Check

every

10

hours al

nininun

(see

fuel

nixture).

Ensure clean fuel

3t alL

times,

DECARBONIZ IiIG

After approxinately

50

hours of

use, the combustion chafiber

may

require de-carbonizing, To

inspect, renove exhaust

socket.

and check for deposits on

piston

cro!{n, Clean

if deposit-

thickness

is in the range of

.04 in.

Procedure:

Remove

cylinder

top cowling

and head. Hold

cylinder

in

place

by suitable means,

Using

a wood scraper,

the

carbon

scales on the corlbustion

chamber of the

cyfinder

head

and on the

top of bhe

piston

should be

removed.

piston

at

top

dead

center.

Reassemble

and re-borque

head.

STO]iACE

If

your

engine

is not

going

to be run for a period

of

'

20 to

J0

days

or

more, certain precautions

nust

be taken

bo

protect

the

engine

and

fuel

system from

heat, direct

sun,

,

corrosion

and the formation

of deoosits.

The

schedule belorr

is a

Buide

for

storage

procedure:

A) I TEnITAL ElrGIr,lE

COI'lPOirEl,tTS

I

Rehove air filtration

6ystem, start

engine

and allow
to idle.
B)

FUEL SYSTEN:
Drain float chamber,

r'enove

fueL

from

tank - drain

fuet

lines.

.1, Follow

all safety

rules

and

do

not run for

a

prolonged

period

above idle.

Using

an

oil-can,

flood

the engine

by injecting

oi1 through

tbe carburetor tilf the

engine stal1s, then

proceed

with

fuel

DJ - !c ur

4rrrf rrt).

AFTER STORAGE CHECX

Ensure all residue

oil

is drained or renoved

by cranking

the

engine, and spark

plug

is cLean

and

gapped.

Iiefill

tank,

purge

fuel

lines

and carburetor float

chamber of air.

Ploceed

with starting engine,

SECTION

12

TROUBLE

SHOOTIIIC

Your

nOTAX engine

requires

two essentials

to run.

Spark

and

cgrrcct fuet/air nixture.

The majority of

probLens quite

often are

a sinple fack

of one or the other.

Organize

yourself

and follow

a set

pattern

to

elininate

sonponents to

find

your

trouble.

Fuel

-

start by checking

the

supply

(tank),

fittings

(loose?),

filter

(ptuEged?),

float

charDber

(fouled?),

Spank

-

try new

plug,

If no

spark, check

ground

wire

on

coil, Enaure

switches

are

not

shorted.

Problems

of

a nore

conplex

nature

are beBt

left to a

ROTAX

engine

technic ian.

st_c'.rIo1t 1J

]]BIAIN

LOG

Iiecord any

lepairs

or

service on

your

ROTAX

enEine and use

)

as a reference.

Iurcbase Date

:

l'irst Use

:

A16,l/-i h Thc^o^ri^-.

R]JPAIR DATE SU].1]'1ARY

OF I'IORIT DOI,IE

nEPAIR

Loc

cont.

REPAIR

DATE

-20-

sur,lllAnY

0F

lfonx

DotjI

sEcTroi'l

14

LICHTING CIRCUIT

The

BOSCH nagneto

generator produces,

apart from the

elec-

tric current required for the

ignition,

7?V

75/21$l

alternating

curent which can be directly

used

for feeding

lights and/or

other users trhat can be operated

with alternating curret.

To

avoid the voltage to rise above

pernissibfe

1eve1s,

either loads anounting to

75/21V

bave

to be

connected,

or

a

voltage regulator has to be

used.

Io

operate loads nequiring direct

current

(e.9.

battery),

a re c tifier-regulator,

part

no. 866 o8o, ia available. For

feeding

lights only, this rect

ifier-regulator can also

be

used

flithout battery. In this case

the

regulated

Rl4S voltage wiLl be

between 11 and 12 Volt

as }ong as a ninimtxl load of 1 arnp.

is

proYided.

In case

of

a bagtery it

has to

be capable

to

absorb

approx,

1 anp. rninirnum conginuos

charging load, even dith full battery

(suggested

rninirnum

battery capacityl

9

anp.h). Regulated

voltage is 11,5

to

14,5 vo1ts.

t

lllAINC-DIACSI!! POn

nECttt'IEn-nEGULA1li 866 080

ln a circult

yltbout

bltl.ry

I|IRIIIO DIIGhAI'I FOi

RECTIFIEN-NEGULITOS 856 O8O

in

conjuncllon

S&!

a

brtt.fy

-22-

rule

151

-i-

-L

TIRINO DIACRAJ' FOR ELECTEIC STAN1ER

fus. 15A

I

o

.lecrrl.-star!.r

WIRTNC

DIAORAM

(not

llbited

!o

r.!t!!1v consuD6r!

(onty)

FOR RECTIFIER-REOULATOR

264 8?O

dlnioud

of 1

Atrpere

consumption)

9IBIllC

DIICnll

foi RECTIFIEn-r.airl.tor

AO{ 8?O

1r a

cl.cult rtthout

battc.y

*IUIC

DtlcFAM

tol IECTIFIEF-.egulato.

26! 870

el,th

a cond.nso.2000

sF)

CD

2o0o

!F

I{tRI}IG

DIA6RA}I FOR

RECTIF]ER.RECULATOR

264

870

ir conjunction rith

e

batt.ry

CD

531

-l-'

16A

T

_,1_

c

?

SE0TION

15

Part

i.cular

Senerator

cable

to

the ignition

WIRINC

DIAGRAM

care has to

be

taken that

(J)

and

the

nass cable

(l{)

coil

(A),

see itlustration.

the

i.gnition

be

correctly

conneqted

c

D

c

TO

connected

generator

coiL

(botton

)

llghting coil 2ll'I

(top)

lighting

coil

75H

contact breaker feve!
breaker contacts
fj,xing scte{

off

the ignit

ibn,

ground,

adj us!Ing

groove

generator

cable

shorting cable
lighting cables
nass cable

ignltion cable

spark

plug pfotector

Ignltion

dampina box

H

J

L
ll
N

o

P

t

cut

lo

the

shorting

cable K has

to be

DAI.'IPINC BO)(
Precaution check:

Connect damping

box with

reverBed

pola-

rity.

There nust be no

spark on the

plug

when cranking

the engine.

If

there is

still a spark, the

darnping

box i5

defectj-ve.

In

case

of ignitign troubles

(no

sparl():

disconnect

damping

box,

if

there is nolr

a spark' the

damping

box is

defective.

If the engine

performance

is bad

r'rith the

damping box

connected

and

good

Nithout it, this indicates

a ueak iSnition

system.

?ossible

cause could bei

Turned

flywheel'

faulty

cgndenser,

faul-by ignition

coif or

spark

plug.

-

z)

-

sEcTroll 16

TECINTCAL

DATA

Specification

-

single cylinder-,

two-sttoke Otto engine,

Cylinder

Stroke

I

Starter

t-

Fuel nix
rat io

I'IAIN

IORQUIIiC

SPEC IFICATIONS

cyl-inder

head

nuts

M8

crankcase

scre!,rs

II8

.

I4a8neto

housinG nut

(Jl1B

x 1,5)

. Crankcase nuts

(or

screws) I'110

i

Exhaust

socket screlis

tl8

lubricated by fueL/oi] nixture,

air cooled

hv f.h ^F fn66 ^iF

-

light a1loy cylinder with

cast iron

aleeve

-?2nm

-

66

rnrn

Dispfacenent

-

263.77

c.c.

.^mhFoeei ^h

-

11 n

rat io
Ignition unit

-

BosCH magneto

generator

scP2

lzc

75/21\l

(a-[ternating

current

)

Ignition

-

z.ot + 2.5J

run BTD0

(0.080 +

0.100

in)

tini!rg
Contact

-

0.10 + 0.40

rnrn

(0.012

+

0.015

in)

hra.kFF dan

Spark

plug

-

BBES or

equivalent

electrode

gap

0.4

i

0.5

nm

(0.015

+

0,020

in.)

Carburetor

-

BII,IG

slide carburetor

54lJ6

Fuel

pump

-

I'IIKUiII

-

renind

starter

or

(on

special order onLy)

revind

starte!,

and electric starter

-

use

50

parta

regular

gasoline

of octane

number

not below I,lOIl6f or nollgo

(unleaded

gas

nay

be

used) to

l

part

oil

lricb

is designed

for

scvere

gervice

in 2 cycle air cooled engines

at nixture

ratios

of

50

: 1 or

greater

with

enphasis

gn

low carbon

production.

Ilm
24

2\

8o

40

2tl

in.lb.

2to

270
7

00

15It
270

Specilicatj.ons

subject to change

r,r-ithout

notice.

C U S TOI'1 ERS,

t

u/85/E

INFORMATION

sept.

85

Mounting-,
for UL-prop

I'laintenance- and safety InEt

ruc tions

gear

on RoTAX engine type 277

))

A

1) Engine

PTo crankcase nust have machined centering

and

q

threads MB.

2)

Th13 paragraph

is onty

appllcable for

execution

'rPropeller

shaft offset towar:dB

cylinderr':

/\-

trib flange

platc

and

O-ring

with 4

cyl.

Fcrews

MB x

25

to

crank-

-

case

PTO

side. Secure the screwbbread

with

LOCTITE

221 llght and

apply LOCTITE 6ltB on

contact surface of tl8 allen-screwheaal,

-

l'orque for screw MBi 20

-

24 Nm or

15 - 18

ft'lb

No

lock

$asber

for

screws

irlB

for,eaeenl

Alt

further

paragraphs

are vaLid for

botb executionsi

-

propeller

shaft offset

towards cylinder

and

-

propelfer

shaft offset towards

engine

base.

Note: Drive

gears

for

the 2

versions

are

different!

Clean

and degrease

taper

of

enBine

PTO shaft careful-ly with

tri

chloroe thylene

or

equivalenti

Degrease also

7/2tt boIL and

PTO

Bhaft thread.

Loctite

221

rankshaft

P.T,O. Side

screw

BOMBARDIER"ROTAX

GESELLSCHAFT M.

B,

H.

MOTOFENFABRIK

A.4623

GUNSKIFCHEN . AUSTRIA

Idlelon:p 12 461271.0'

Tor€x: 25 5a6 bom'ol .

I.rqqrdhrn!d,6s.:

goMaRorAx

clJNsxrRcl.lEN

I

2

a

Aqr

Fix

sprocket with

1/2"

bolt,

waaher and

lock washer,

use Loctite

221

(light)

only on thread.

Mounlr the

oi.I.

sfinger

between

washer

and

Lock

washer,

Torque

for 7/2,t

bolEt 41

+ 45 ft.1b

or

55

+

dO Nn

Bott

gear

assy

with

ituds, lock

washer and

O-ring on

flange

plate,

5-6

15-18

t

Torque

for

studs

HB

Torque

for

nuts

M8

fnspect correct position

of

Yc'iu yru6

\

LUP,/.

Secure drain

plug

with wire.

ft.lb

or

7-B

Nn

ft.lb

or

2o-2lt

Nm

oi.1

draln

plug (botton)

anal

A

rz)

9el4r

safety

is everyone's

business.

Help

to

assure

secure

ancl

troublefree

operation

by

observing'the

above

instructions,

fn

case

of doubt

contact your

autiorized

workshop.

I

fi)

Mounting

and

maintenance

operations

nust

be done

onty by

sl<ilfed personnel.

Af4)

suf"ty

warning.symbot

I

I

nailure

to

obey

a safety

warning

may

result

in

injury

to

you

or

others.

3

u/ 85/E

Arr

Aer

7) only applicable

for

execution

with

separate

prop.

fLante!

Degrease

gear

PTO

shaft, thread

and bolt

M12 x 1,5

LII

(1eft

hand)

l4ount

propeLler

hub

with Loctit,e

ZlfZ

(light)

on

taper and

t hre ad

Torque:

41 - 45 ft,lb

or

55-60

m

Attention:

left

hand thread !

B) Prop

hub

is for 6 x

1,/4'r

botts

(or

6 x l4B),

no

botts

supplied

by Rotax,

9)

Fil1

gear

oil SAE

9o-API-GL

5

into

gear

box

(for

both

directlons)

ol

prop

shaft

-

above

and below

crankshaft

axis)

up to

loner

oiI 1eve1

plug.

Secure

venb

plug

with

wire,

10) Preflight

Ins tructions

At t

ention I

As

supplied

by the

factory,

irrespective

whebher

gear_box

is loose

or

rnounted

on

engine,

ttrire

is

"o

oii-iiir.a

into

the

gear-box.

Fil1

in oil,

Secure

alrain

ptug,

yent

plug

and

oil

.tevel

screws

with

wire

before

usel

Check

tightness

of nountlng

bolta

and

nuts,

|

11)

Main

tenancu

(

every

10

operating

hours)

Check

oiI

volume

on

respectlve

oil level

screw

and

secure

again with

nire.

Change

oi1

after 1sb

10

hours

of

oDeration.

Change

oil

every 100

hours

or every

2

years

(which

occurs

firs t

),

Check

if

propeller

tip

clearance

is as

usual.

;

:i

Sept. 19 85

ENGIiIE

TYPE:

SERIAL

NO.:

PURCHASE

DATE

I

IiISTALLATION

IN:

I

t

t

t

DEALER

II4PRINT

AREA

BOMBARDIER-ROTAX GMBH

MOTORENFABFIK

A-4623

Gunskirchen

=Austria

T€lelon:

(07246)

271-0'.

relex:

25546 brgk

a

Telegrammadresse: Eombrotax Gunskirchen

b

F

$