rickofudall
Joined: 19 Sep 2009
Posts: 1392
Location: Udall, KS, USA
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 Posted: Sun Nov 22, 2009 7:49 am Post subject: RotaxEngines-List: Re: Rotax 503 service manual |
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I went to the Rotax Austrian site. No overhaul manual is available, same for a Heavy Maintenance Manual. The only HMM available at Rotax classes (at least at Lockwood) is the HMM for the 462, 532, 582 series water cooled engines. This too is unavailable from Rotax Gmbh. Here's the only thing that comes close (attached). I recommend you go the the Rotax owners site and get the Illustrated Parts Catalog too. It's too big to send as an attachment. It has torque tables for all the screws and bolts used and schematic drawings with a parts list for each section of the engine.
BEWARE the tap tight screw. You can tell this baby by the three lobe shape of the threads. It's a self tapper and has a MUCH lower torque requirement than a regular screw. This is where the IPC is indispensable, IMHO, because it will identify exactly where it is used in the parts list that accompanies the breakdown drawing.
If you are keeping this engine long term you might want to consider swapping out the points for a CDI.
Last make sure the plug gap is .018", not looks right, Rotax ignitions have a notoriously weak spark. Get an inline spark checker ($2 from Harbor Freight, more money to the Chicoms but we're in so deep, now....) It's almost impossible to see a Rotax spark at the plug and while a points ignition will survive if you don't have a good ground, a CDI won't. (big buck, many flowers to wife, etc, etc.)
Good luck,
Rick
On Sun, Nov 22, 2009 at 4:55 AM, Dave G <occom(at)ns.sympatico.ca (occom(at)ns.sympatico.ca)> wrote:
[quote]--> RotaxEngines-List message posted by: "Dave G" <occom(at)ns.sympatico.ca (occom(at)ns.sympatico.ca)>
Here is a link for the support documents for your engine.
http://www.rotax-owner.com/index.htm
Under support.
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