MM 447 503 582 D00370 D00288

User Manual: D00370

Open the PDF directly: View PDF .
Page Count: 60

Download
Open PDF In Browser	View PDF

AIRCRAFT ENGINES

MAINTENANCE MANUAL

1)

Table of contents ...................................................................................................... 2
2)
3)
4)
5)

Index ...................................................................................................................... 2 - 1
List of the current pages ..................................................................................... 3 - 1
Table of amendments .......................................................................................... 4 - 1
Introduction .......................................................................................................... 5 - 1
5.1)
5.2)

6)

Safety .................................................................................................................... 6 - 1
6.1)
6.2)
6.3)

7)

Use for intended purpose ................................................................................... 7 - 1
Instruction .......................................................................................................... 7 - 1

General .................................................................................................................. 8 - 1
8.1)
8.2)

8.3)

9)

Repeating symbols ............................................................................................. 6 - 1
Safety information .............................................................................................. 6 - 1
General operating and safety instructions .......................................................... 6 - 3

Technical documentation .................................................................................... 7 - 1
7.1)
7.2)

8)

Remarks ............................................................................................................. 5 - 2
Engine serial number .......................................................................................... 5 - 2

Description ......................................................................................................... 8 - 1
Technical data .................................................................................................... 8 - 1
8.2.1)
447 UL SCDI ..................................................................................... 8 - 1
8.2.2)
503 UL DCDI ..................................................................................... 8 - 3
8.2.3)
582 UL DCDI and 582 UL DCDI mod.99 ............................................ 8 - 5
Components ....................................................................................................... 8 - 8
8.3.1)
447 UL SCDI ..................................................................................... 8 - 8
8.3.2)
503 UL DCDI ..................................................................................... 8 - 9
8.3.3)
582 UL DCDI ................................................................................... 8 - 10

Maintenance .......................................................................................................... 9 - 1
General proceeding instructions ......................................................................... 9 - 1
Trouble shooting ................................................................................................. 9 - 1
Basic information ............................................................................................... 9 - 2
Auxiliary tools .................................................................................................... 9 - 2
Measuring tools .................................................................................................. 9 - 2
Special tools and devices .................................................................................. 9 - 3
Consumable materials ........................................................................................ 9 - 3
9.7.1)
Two stroke oil .................................................................................... 9 - 3
9.7.2)
Lithium grease .................................................................................. 9 - 3
9.7.3)
Multi-purpose grease LZ .................................................................... 9 - 3
9.7.4)
Corrosion inhibiting oil MOBILARMA 524 .......................................... 9 - 3
9.7.5)
Grease MOLYKOTE G-N ................................................................... 9 - 3
9.7.6)
LOCTITE Anti-Seize 76710 ............................................................... 9 - 3
9.7.7)
SILASTIC .......................................................................................... 9 - 3
9.7.8)
LOCTITE "574 orange" ..................................................................... 9 - 4
9.7.9)
LOCTITE "648 green" ....................................................................... 9 - 4
9.7.10)
LOCTITE "221 violet" ........................................................................ 9 - 4
9.7.11)
MICRONORM shot blasting abrasive ................................................ 9 - 4
9.7.12)
Lapping fleece SR 4600 A - very fine grading ................................... 9 - 4

d00288

9.1)
9.2)
9.3)
9.4)
9.5)
9.6)
9.7)

Effectivity: 447 UL SCDI, 503 UL DCDI, 582 UL DCDI /mod. 99

page 1 - 2
Initial issue, May 01/99

AIRCRAFT ENGINES

MAINTENANCE MANUAL

9.8)

9.10)
9.11)

10)

Maintenance Checks .......................................................................................... 10 - 1
10.1)
10.2)

11)

9.7.13)
Cleaning agents ................................................................................ 9 - 5
Securing elements ............................................................................................. 9 - 5
9.8.1)
Safety wiring ..................................................................................... 9 - 5
9.8.2)
Nut securing ...................................................................................... 9 - 7
Treatment of corrosion and surface damages ..................................................... 9 - 8
Engine preservation and engine back to operation ............................................. 9 - 8
Periodical maintenance .................................................................................... 10 - 1
Maintenance Schedule ..................................................................................... 10 - 2

Maintenance of the various systems: .............................................................. 11 - 1
11.1)
11.2)
11.3)
11.4)
11.5)

11.6)
11.7)
11.8)
11.9)
11.10)
11.11)
11.12)
11.13)
11.14)
11.15)
11.16)
11.17)

11.18)
11.19)
11.20)
11.21)
11.22)
11.23)
11.24)
11.25)
11.26)
11.27)
11.28)
11.29)
11.30)
11.31)

d00288

11.33)
11.32)

Ground test ...................................................................................................... 11 - 1
Level check of liquids ....................................................................................... 11 - 1
Retorque cylinder head nuts (only on 447 UL SCDI and 503 UL DCDI) ............ 11 - 2
Retorque of exhaust manifold screws: ............................................................. 11 - 2
Checking of the rewind starter rope .................................................................. 11 - 2
11.5.1)
Rewind starter dismantling: ............................................................. 11 - 3
11.5.2)
Rewind starter reassembly: ............................................................ 11 - 3
Check electric starter gear ............................................................................... 11 - 3
Inspection of spark plugs ................................................................................. 11 - 3
Replacement of spark plugs ............................................................................. 11 - 4
Check of the ignition system ............................................................................ 11 - 5
Check and clean inside of spark plug connectors ............................................ 11 - 5
Checking of V - belt tension (only on fan cooled 441 and 503 engines) ............ 11 - 6
Lubricate Ball joints .......................................................................................... 11 - 6
Replace exhaust muffler springs ...................................................................... 11 - 6
Lubricate control cables ................................................................................... 11 - 7
Check propeller balance and tracking ............................................................... 11 - 7
Inspect propeller mounting bolts ...................................................................... 11 - 7
Clean and oil air filter ........................................................................................ 11 - 7
11.17.1) Application of new air filters: ........................................................... 11 - 7
11.17.2) Cleaning of used air filters: ............................................................. 11 - 8
Check and replacement of fuel filter ................................................................. 11 - 8
Clean carburetors and check for wear .............................................................. 11 - 8
Replace jet needle and needle jet ..................................................................... 11 - 9
Clean and check fuel pump .............................................................................. 11 - 9
Check gearbox oil level, replace gearbox oil .................................................... 11 - 9
Checking and adjusting of gearbox, preload of springs (B- type gearbox) ....... 11 - 10
Renewing of the rotary valve lubrication oil (582 UL DCDI /mod. 99 only) ....... 11 - 11
Inspection of the cylinder head and piston crown ............................................ 11 - 11
Inspection of the piston rings .......................................................................... 11 - 11
Check piston diameter .................................................................................... 11 - 12
Piston ring, checking of gap and axial play ..................................................... 11 - 13
Checking of cylinder diameter and roundness ................................................. 11 - 14
Replace cylinder head-, cylinder base- and exhaust gaskets .......................... 11 - 15
Inspect pins and bearings ............................................................................... 11 - 15
11.31.1) Piston pin: ..................................................................................... 11 - 15
11.31.2) Piston pin bearing: ......................................................................... 11 - 15
General overhaul of the engine ........................................................................ 11 - 16
Inspect crankshaft and replace outer seals ..................................................... 11 - 16

Effectivity: 447 UL SCDI, 503 UL DCDI, 582 UL DCDI /mod. 99

page 1 - 3
Initial issue, May 01/99

AIRCRAFT ENGINES

MAINTENANCE MANUAL

12)

Required inspections after limits of operation have been exceeded: .......... 12 - 1
12.1)
12.2)
12.3)
12.4)

12 - 1
12 - 1
12 - 2
12 - 2

ROTAX® Authorized Distributors ..................................................................... 13 - 1

d00288

13)

Exceeding of max. permissible engine speed ..................................................
Exceeding of max. permissible cylinder head temperature ...............................
Exceeding of max. permissible exhaust gas temperature ................................
Fuel pressure below specified value .................................................................

Effectivity: 447 UL SCDI, 503 UL DCDI, 582 UL DCDI /mod. 99

page 1 - 4
Initial issue, May 01/99

AIRCRAFT ENGINES

MAINTENANCE MANUAL

2) Index
A

F

N

Air filter 11 - 7
Auxiliary tools 9 - 2

Fuel filter 11 - 8
Fuel pressure 12 - 1
Fuel pump 11 - 9

Needle jet 11 - 9
Nut securing 9 - 6

G

Oil control cables 11 - 7
Operating-hours-related checks
10 - 1
Oscilloscope 9 - 2

B
Ball joints 11 - 6
Basic information 9 - 2
Bearings 11 - 15

C
Carburetors 11 - 8
Cleaning agents 9 - 5
Components 8 - 8
Consumable materials 9 - 3
Crankshaft 11 - 16
Current pages 3 - 1
Cylinder diameter and roundness 11 - 14
Cylinder head and piston crown
11 - 11
Cylinder head nuts 11 - 2
Cylinder head temperature 12 1

D
Documentation 7 - 1

E

I
Ignition system 11 - 5
Index 2 - 1
Introduction 5 - 1

J
Jet 11 - 9

L
Lapping fleece 9 - 4
Level check of liquids 11 - 1
Limits of operation 12 - 1
Lithium grease 9 - 3
LOCTITE 9 - 3

M
Maintenance 9 - 1
Maintenance Checks 10 - 1
Maintenance of the varions
systems 11 - 1, 12 - 1
Maintenance Schedule 10 - 2
Measuring tools 9 - 2
MOLYKOTE 9 - 3
Multimeter 9 - 2

P
Periodical maintenance 10 - 1
Pins 11 - 15
Piston diameter 11 - 12
Piston rings 11 - 11
Propeller balance and tracking
11 - 7
Propeller mounting bolts 11 - 7
Propeller shaft 9 - 7
PU adhesive 9 - 3

R
Retorque cylinder head nuts 11
-2
Retorque of exhaust manifold
screws 11 - 2
Rewind starter rope 11 - 3
Rotary valve lubrication 11 - 11
ROTAX® Authorized Distributors
13 - 1

d00368

Electric starter gear 11 - 3
Electric system 9 - 7
Engine speed 12 - 1
Exhaust gas temperature 12 1
Exhaust manifold screws 11 2
Exhaust muffler springs 11 - 6

Gasket 11 - 15
Gearbox 11 - 9
General 8 - 1
General overhaul of the engine
11 - 16
Grease 9 - 3
Ground test 11 - 1

O

Effectivity: 447 UL SCDI, 503 UL DCDI, 582 UL DCDI /mod. 99

page 2 - 1
Initial issue, May 01/99

AIRCRAFT ENGINES

MAINTENANCE MANUAL

S
Safety 6 - 1
Safety information 6 - 1
Safety instructions 6 - 3
Safety wiring 9 - 5
Seasonal checks 10 - 1
Securing elements 9 - 5
SILASTIC 9 - 3
Spark plug connectors 11 - 5
Spark plugs 11 - 3, 11 - 4
Special tools and devices 9 - 3
Stroboscope 9 - 2

T
Table of amendments 4 - 1
Table of contents 1 - 2
Technical data 8 - 1
Technical documentation 7 - 1
Trouble shooting 9 - 1
Two stroke oil 9 - 3

U
Used air filters 11 - 8

V

d00368

V - belt tension 11 - 6
Vernier callipers 9 - 2

Effectivity: 447 UL SCDI, 503 UL DCDI, 582 UL DCDI /mod. 99

page 2 - 2
Initial issue, May 01/99

AIRCRAFT ENGINES

MAINTENANCE MANUAL

3) List of the current pages
section

date

section

page

date

10

10 - 1
10 - 2

99 05 01
99 05 01

11

11 - 1
11 - 2
11 - 3
11 - 4
11 - 5
11 - 6
11 - 7
11 - 8
11 - 9
11 - 10
11 - 11
11 - 12
11 - 13
11 - 14
11 - 15
11 - 16

99 05 01
99 05 01
99 05 01
99 05 01
99 05 01
99 05 01
99 05 01
99 05 01
99 05 01
99 05 01
99 05 01
99 05 01
99 05 01
99 05 01
99 05 01
99 05 01

99 05 01
99 05 01

12

12 - 1
12 - 2

99 05 01
99 05 01

8-1
8-2
8-3
8-4
8-5
8-6
8-7
8-8
8-9
8 - 10

99 05 01
99 05 01
99 05 01
99 05 01
99 05 01
99 05 01
99 05 01
99 05 01
99 05 01
99 05 01

13

13 - 1
13 - 2
13 - 3

99 05 01
99 05 01
99 05 01

9-1
9-2
9-3
9-4
9-5
9-6
9-7
9-8

99 05 01
99 05 01
99 05 01
99 05 01
99 05 01
99 05 01
99 05 01
99 05 01

1-1
1-2
1-3
1-4

99 05 01
99 05 01
99 05 01
99 05 01

2

2-1
2-2

99 05 01
99 05 01

3

3-1
3-2

99 05 01
99 05 01

4

4-1
4-2

99 05 01
99 05 01

5

5-1
5-2

99 05 01
99 05 01

6

6-1
6-2
6-3
6-4

99 05 01
99 05 01
99 05 01
99 05 01

7

7-1
7-2

8

9

d00369

1

page

02773

Effectivity: 447 UL SCDI, 503 UL DCDI, 582 UL DCDI /mod. 99

page 3 - 1
Initial issue, May 01/99

AIRCRAFT ENGINES

MAINTENANCE MANUAL
02773

page

date

section

page

date

d00369

section

Effectivity: 447 UL SCDI, 503 UL DCDI, 582 UL DCDI /mod. 99

page 3 - 2
Initial issue, May 01/99

AIRCRAFT ENGINES

MAINTENANCE MANUAL

4) Table of amendments
section

0

1 ÷ 13

page
all

date
of
change

remark for
approval

99 05 01

not required

date of
approval from
authorities

date
of
issue

signature

99 05 01

AA/HeC

d00370

no.

02774

Effectivity: 447 UL SCDI, 503 UL DCDI, 582 UL DCDI /mod. 99

page 4 - 1
Initial issue, May 01/99

AIRCRAFT ENGINES

MAINTENANCE MANUAL
02773

section

page

remark for
approval

date of
approval from
authorities

date
of
issue

signature

d00370

no.

date
of
change

Effectivity: 447 UL SCDI, 503 UL DCDI, 582 UL DCDI /mod. 99

page 4 - 2
Initial issue, May 01/99

AIRCRAFT ENGINES

MAINTENANCE MANUAL

5) Introduction
Thank you for using a ROTAX® aircraft engine.
Before carrying out maintenance work on the engine, carefully read the Maintenance Manual.
It provides you basic information on safe operation of the engine.

d00371

If any passages of the Manual are not understood or in case of any questions, please, contact
an authorized Distribution- or Service Centers for ROTAX® aircraft engines.

Effectivity: 447 UL SCDI, 503 UL DCDI, 582 UL DCDI /mod. 99

page 5 - 1
Initial issue, May 01/99

AIRCRAFT ENGINES

MAINTENANCE MANUAL

5.1)

Remarks
The purpose of this Manual is to familierize the maintenance staff approved by the
local aviation authorities with some basic maintenance and safety information.
For competent maintenance and servicing, please, refer to the documentation
provided in the Operator's Manual, Installation Manual and Illustrated Parts Catalog.
For additional engine-, maintenance- and parts information you may also contact the
nearest ROTAX® aircraft engine distribution partner.

5.2)

Engine serial number

d00371

On all enquiries or spare parts orders, always indicate the engine serial number, as
the manufacturer makes product improvement modification to the engine. The engine
serial number is located on the top of the crankcase, magneto side or the ignition
cover (see fig. 001, 002, 003).

Effectivity: 447 UL SCDI, 503 UL DCDI, 582 UL DCDI /mod. 99

page 5 - 2
Initial issue, May 01/99

AIRCRAFT ENGINES

MAINTENANCE MANUAL

6) Safety
Although the mere reading of such an instruction does not eliminate a hazard, the understanding and application of the information will promote correct use.
The information and components-/system descriptions contained in this Maintenance
Manual are correct at the time of publication. ROTAX®, however, maintains a policy of
continuous improvement of its products without imposing upon itself any obligation to install
them on its products previously manufactured.
ROTAX® reserves the right at any time to discontinue or change specifications, designs,
features, models or equipment without incurring obligation.
The illustrations in this Maintenance Manual show the typical construction. They may not
represent in full detail or the exact shape of the parts which have the same or similar function.
Specifications are given in the SI metric system with the USA equivalent in brackets. Where
precise accuracy is not required, some conversions are rounded off for easier use.

6.1)

Repeating symbols
This Manual uses the following symbols to emphasize particular information. These
indications are important and must be respected.
▲ WARNING:

Identifies an instruction which, if not followed, may cause
serious injury including the possibility of death.

■ ATTENTION: Denotes an instruction which, if not followed, may severely
damage the engine or other component.
◆ NOTE:

6.2)

Indicates supplementary information which may be needed to
fully complete or understand an instruction.

Safety information
▲ WARNING:

This engine, by its design, is subject to sudden stoppage! Engine
stoppage can result in forced landings, no power landings or crash
landings. Such crash landings can lead to serious injury or death.

▲ WARNING:

Never fly the aircraft equipped with this engine at locations, airspeeds, altitudes, of other circumstances from which a successful
no-power landing cannot be made, after sudden engine stoppage.
Aircraft equipped with this engine must only fly in DAYLIGHT VFR
conditions.

▲ WARNING:

This is not a certificated aircraft engine. It has not received any
safety or durability testing, and conforms to no aircraft standards.
It is for use in experimental, uncertificated aircraft and vehicles only
in which an engine failure will not compromise safety.

d00372

User assumes all risk of use, and acknowledges by his use that he
knows this engine is subject to sudden stoppage.

Effectivity: 447 UL SCDI, 503 UL DCDI, 582 UL DCDI /mod. 99

page 6 - 1
Initial issue, May 01/99

AIRCRAFT ENGINES

MAINTENANCE MANUAL

☞ It should be clearly understood that the choice, selection and use of this particular
engine on any aircraft is at the sole discretion and responsibility of the aircraft
manufacturer, assembler and owner/user.
☞ Due to the varying designs, equipment and types of aircraft, ROTAX® makes no
warranty or representation on the suitability of its engine’s use on any particular
aircraft. Further, ROTAX® makes no warranty or representation of this engine’s
suitability with any other part, component or system which may be selected by
the aircraft manufacturer, assembler or user for aircraft application.
☞ You should be aware that any engine may seize or stall at any time. This could
lead to a crash landing and possible severe injury or death. For this reason we
recommend strict compliance to the maintenance, operation and any additional
information which may be given to you by your dealer.
☞ Select and use proper aircraft instrumentation. This instrumentation is not
included in the ROTAX® engine package. Only approved instrumentation can be
installed.
☞ Unless in a run-up area, never run the engine with the propeller turning while on
the ground. Do not operate engine if bystanders are close.
☞ To prevent unauthorized use, never leave the aircraft unattended with the engine
running.
☞ Keep an engine log and respect engine and aircraft maintenance schedules.
Keep the engine in top operating condition at all times. Do not operate any aircraft
which is not properly maintained or has engine operating irregularities which have
not been corrected.
☞ Keep an engine log and enter any unusual engine behaviour. Do not fly unless you
have corrected a given problem and recorded the remedy in the log.
☞ Since special tools and equipment may be required, engine servicing should only
be performed by an authorized ROTAX® engine dealer or a qualified trained
mechanic approved by the local airworthiness authority.
☞ To eliminate possible injury or damage, ensure that any loose equipment or tools
are properly secured before starting the engine.
☞ Never leave your aircraft or other vehicle unattended while the engine is running.
If operated by someone else you could be sued even if the use was unauthorized by you.
☞ When in storage protect the engine and fuel system from contamination and
exposure.
☞ Never operate the engine and gearbox without sufficient quantities of lubricating
oil.
☞ Never exceed maximum rated rpm. and allow the engine to cool at idle for several
minutes before turning off the engine.

Effectivity: 447 UL SCDI, 503 UL DCDI, 582 UL DCDI /mod. 99

page 6 - 2
Initial issue, May 01/99

d00372

☞ Periodically verify level of coolant on 582 UL DCDI and 582 UL DCDI mod. 99.

AIRCRAFT ENGINES

MAINTENANCE MANUAL

☞ Operating the engine at high rpm. at low throttle position, for example during
descent, may increase engine and exhaust temperatures and cause critical
overheating. Always compensate and match rpm. with throttle position.
☞ Maintain your engine in top condition and assume it's going to quit running at any
time. Leave yourself a way out in the event of unexpected failure.
☞ Never mix fuel in an enclosed area, or where fumes could reach the ignition point.
☞ Make sure all engine controls are operative, that you know ON and OFF positions
of throttle and ignition, that they are easily accessible, and that you can operate
them instinctively without hesitation.
☞ Never refuel if fuel could be spilled on hot engine components. Use only safety
approved fuel containers and never transport fuel in an unsafe manner.
☞ Check engine suspension frequently as well as the drive components, fuel lines,
wiring, and fuel and air filters.
☞ Check for fuel contamination, air vents, etc. Protect engine while not in use from
any contamination entering fuel or carburetion system, but be sure to remove
storage protection before starting the engine.

6.3)

General operating and safety instructions
☞ Please, observe besides the instructions in our documentation also the generally
valid safety- and accident preventive prescriptions and legal regulations as well
as the relevant regulations by the competent aeronautical authorities.
☞ The information contained in the Maintenance Manual is based on data and
experience and is considered to be applicable for a professional technician under
normal working conditions. The instructions given in the Maintenance Manual are
useful and necessary supplements to personal instruction, but can by no means
substitute theoretical and practical personal instruction.
☞ The manufacturer or supplier has no influence on the personnel and operational
conditions of the buyer and assumes no responsibility for sustaining effect of the
personal instructions.
☞ We point to the fact that spare parts and accessories not supplied as genuine
ROTAX® parts are not tested and therefore not released by ROTAX®. Installation
and/or use of such products may change and negatively affect the constructive
properties of the engine. For damages due to use of non-genuine parts and
accessories ROTAX® refuses any liability.
☞ Unauthorized modifications and use of components or accessories not corresponding with the installation instructions exclude any liability of the manufacturer.

d00372

☞ The engine is accurately tested before delivery, this however does not exclude
hazards in case of incompetent handling.
☞ Before taking the engine into operation, make yourself familiar with the respective
controls and their function. Searching during operation is too late! In case of
vibrations or unusual noise, stop the engine and remedy the cause.
Effectivity: 447 UL SCDI, 503 UL DCDI, 582 UL DCDI /mod. 99

page 6 - 3
Initial issue, May 01/99

AIRCRAFT ENGINES

MAINTENANCE MANUAL

☞ Attention when draining hot oil: Danger of scalds!
☞ Disposal of used oil, fuels and filters as per local regulations.
☞ Liquids emerged (fuel or acids) can penetrate the skin and cause bad caustic
injury. In case of accident immediately consult a doctor as bad infections may be
engendered.
☞ Cleaning the engine with lye or alkaline solutions is forbidden, as a matter of
principle. Use of a high pressure cleaner may cause engine failures and rust
formation.
☞ When working on the electric system and on the engine, first detach the cable of
the minus-pole and then of the plus-pole of the battery! When connecting the
cables, first connect the plus- and then the minus-pole.
☞ Firmly attach the engine removed from the aircraft on an assembly trestle.
☞ Do not let the engine run in a closed room (poisoning hazard)!
☞ Always observe the engine while running from a secure place.
☞ When stopping the engine, switch off ignition and remove ignition key.
☞ Before refuelling, always stop the engine and remove ignition key. Do not refuel
in closed rooms. Immediately clean off spilt fuel.
☞ At handling of fuel be very careful - increased fire danger! Never refuel in the
vicinity of open flames or sparks able to ignite. Do not smoke when refuelling.

d00372

☞ Only use oil and fuel of the specified quality and store them in approved
containers only.

Effectivity: 447 UL SCDI, 503 UL DCDI, 582 UL DCDI /mod. 99

page 6 - 4
Initial issue, May 01/99

AIRCRAFT ENGINES

MAINTENANCE MANUAL

7) Technical documentation
The information given in the
— Installation Manual
— Operator's Manual
— Maintenance Manual
— Service Informations
— Spare Parts List
is based on data and experience that are considered applicable for professionals under
normal conditions.
■ ATTENTION: Due to the fast technical progress and fulfilment of particular specifications
of the customers, it may occur that existing laws, safety prescriptions,
constructional and operational regulations cannot be transferred completely to the object bought, in particular for special constructions, or may
not be sufficient.
◆ NOTE:

The illustrations in this Maintenance Manual are stored in a graphic data file
and are provided with a consecutive irrelevant number.
This number (00123) is of no significance for the content.

7.1)

Use for intended purpose
☞ The engines are intended for use in non certified aircraft. In case of doubt the
regulations of the national authorities or the respective sportive federations have
to be observed.
☞ Use for intended purpose also means respecting the prescribed operationalmaintenance and repair conditions. This also increases the engine lifetime.
☞ Never run the engine without propeller, this causes inevitably engine damage and
hazard of explosion.

7.2)

Instruction
Engines require instructions regarding their application, use, operation, maintenance
and repair.
Technical documentation and directions are useful and necessary complementary
elements for personal instruction, but can by no means substitute theoretical and
practical instructions. These instructions should cover explanation of the technical
context, advice for operation, maintenance, use and operational safety of the engine.

d00373

☞ This engine must only be operated with accessories supplied, recommended and
released by ROTAX®. Modifications are only allowed after consent by the engine
manufacturer.

Effectivity: 447 UL SCDI, 503 UL DCDI, 582 UL DCDI /mod. 99

page 7 - 1
Initial issue, May 01/99

AIRCRAFT ENGINES

MAINTENANCE MANUAL

■ ATTENTION: Spare parts must meet with the requirements defined by the engine
manufacturer. This is only warranted by use of GENUINE ROTAX®
parts and/or accessories (see illustrated parts catalog).
They are available only at the authorized ROTAX® Distribution- and
Service partners.

d00373

If using other than GENUINE ROTAX® parts and/or accessories,
any warranty by ROTAX® becomes void (see Warranty Conditions).

Effectivity: 447 UL SCDI, 503 UL DCDI, 582 UL DCDI /mod. 99

page 7 - 2
Initial issue, May 01/99

AIRCRAFT ENGINES

MAINTENANCE MANUAL

8) General
The engine in principle consists of several main components and auxiliary units described
in the following paragraphs.

8.1)

Description
Refer to section 7 in the current Operator’s Manual 447 UL SCDI - 503 UL DCDI - 582
UL DCDI mod. 99.

8.2)

Technical data
8.2.1)

447 UL SCDI
Description:

Bore:
Stroke:
Displacement:
Compression ratio:
Power output: 1-carburetor:
Max. torque:
Max. rpm:
Direction of engine rotation:

Cylinder:
Piston:
Piston/cylinder clearance:
Ignition system:

Generator output:
Ignition timing:
Spark plug:
Electrode gap:
Carburetor:

d00374

Fuel pump:
Fuel:

Two-cycle, two-cylinder in line
egine, mixture lubrication, fancooled
or free air cooled
67,5 mm (2,657 in.)
61 mm (2,40 in.)
436,5 ccm (26,635 cu.in.)
theoretical 9,6 effective 6,3
29,5 kW (40,0 HP) at 6500 RPM
approx. 46 Nm at 6000 RPM.
6800 RPM.
counter-clockwise, viewed towards
p.t.o. (without reduction gear-box)
2 light alloy cylinders with cast iron
sleeves
Cast aluminium piston with 2 piston
rings
0,05 (.00197 in.)
breakerless DUCATI capacitor
discharge single ignition with magneto generator
170 W AC at 6000 1/min. and 13,5 V
1,88 mm = .0740 in. (18 O) B.T.D.C.
14 mm, BR8ES
0,5 mm (.02 in.)
BING 36 mm (1,417 in.), cable
choke
pneumatic fuel pump DF 44
regular Gasoline, octane number
not below MON 83 or RON 90
(unleaded preferred)

Effectivity: 447 UL SCDI, 503 UL DCDI, 582 UL DCDI /mod. 99

page 8 - 1
Initial issue, May 01/99

AIRCRAFT ENGINES

MAINTENANCE MANUAL

Lubrication oil of engine:

SUPER 2-stroke oil (for high performance air cooled 2-cycle engines, proposed ASTM/CEC standard API-TC) mixing ratio 1 : 50 (2
per cent)

Lubrication oil of gear-box:

Gear oil, API-GL5 or GLSAE 140
EP, or 85 W - 140 EP

Starter:

Rewind Starter

Direction of prop. shaft rotation:

clockwise, viewed towards propeller flange

Cooling:

Fan cooled or free air cooled

Weight:

Engine without carburetor, intake
silencer, fuel pump, exhaust system: 26,80 kg (59,00 lb.)

Optional features: Intake silencer: for l-carburetor engine version
■ ATTENTION: If engine is supplied without intake silencer, the
carburetor calibration must be modified for use with intake silencer.
After-muffler:

After-muffler to be fitted in addition
to the standard muffler.

Air filter:

l) to be fitted directly on carburetor
2) to be fitted on the intake silencer

Electric starter:

electric starter, magneto side,
without rewind starter (gearbox is
possible)

Rectifier-regulator:

1) 866 080 requires minimum load
of 12 V (l Amp) to regulate
2) 264 870 no minimum load is required

Reduction gearbox:

with torsional shock absorber

type „B“:

ratios available: i= 2,0 / 2,24 / 2,58 /
3,0 max. allowed moment of inertia
of propeller: 3000 kg cm 2
ratios available: i= 2,62/3,0/3,47/4,0

type „C“:

High altitude compensator:

Effectivity: 447 UL SCDI, 503 UL DCDI, 582 UL DCDI /mod. 99

automatic high altitude adjustment
of carburetor calibration, with modified carburetor (on request)
page 8 - 2
Initial issue, May 01/99

d00374

max. allowed moment of inertia of
propeller: 6000 kg cm 2

AIRCRAFT ENGINES

MAINTENANCE MANUAL

8.2.2)

503 UL DCDI
Description:

Bore:
Stroke:
Displacement:
Compression ratio:
Power output:

Max. torque:
Max. rpm:
Direction of engine rotation:
Cylinder:
Piston:

Piston/cylinder clearance:
Ignition system:

Generator output:
Ignition timing:
Spark plug:
Electrode gap:
Carburetor:
Fuel pump:
Fuel:

d00374

Lubrication oil of engine:

two-cycle two cyl. engine in
line, mixture lubrication or oil injec
tion lubrication, fan cooled or free
air cooled.
72,0 mm (2,84 in.)
61 mm (2,40 in.)
496,7 ccm (30,31 cu.in.)
theoretical 10,8
a) single carb.: 34,0 kW (46 hp)
at 6500 RPM
b) twin carb.: 37,0 kW (50,0 hp ) at
6600 RPM
a) 51 Nm
b) 55 Nm
6800 RPM.
counter-clockwise, viewed towards
p.t.o. (without reduction gear-box)
2 light alloy cylinders with cast iron
sleeves
Cast aluminium piston with 2 piston
rings, one semi-trapez ring (top)
and one rectangular ring
0,07 ÷ 0,08 mm (.0028 ÷ .0032 in.)
breakerless DUCATI capacitor discharge dual ignition with magneto
generator.
170 W AC at 6000 RPM and 13,5 V
1,47 mm = .059 in. (16 O) BTDC
14 mm, BR8ES
0,4 ÷ 0,5 mm (.016 ÷ .02 in.)
2 x Bing 36 mm (1,42 in.), cable
choke
pneumatic fuel pump DF 52
regular Gasoline, octane number
not below MON 83 or RON 90
(unleaded prefered)
1) oil-in-fuel with Super-two stroke
oil, proposed ASTM/CEC standard
API-TC, mixing ratio 1:50 (2%)
2) by oil pump (optional) with the
same oil
■ Attention: pour point 10 O C below lowest operating temperature

Effectivity: 447 UL SCDI, 503 UL DCDI, 582 UL DCDI /mod. 99

page 8 - 3
Initial issue, May 01/99

AIRCRAFT ENGINES

MAINTENANCE MANUAL

Lubrication oil of gear-box:
or

Gear oil, API-GL5 or GL6 SAE 140 EP,
85 W - 140 EP

Starter:

Rewind starter

Direction of prop. shaft rotation:

Clockwise, viewed towards propeller flange

Cooling:

Air cooled by axial fan, or free air for
special applications

Weight without carburetor, intake silencer, fuel pump, exhaust system:
30,4 kg (67,0 lb.)
Optional features:
After-muffler:

After-muffler to be fitted in addition
to the standard muffler.

Air filter:

l) to be fitted directly on carburetor
2) to be fitted on the intake silencer

Electric starter:

1) electric starter, magneto side,
without rewind starter (gearbox is
possible)
2) electric starter on “E” type gearbox

Rectifier-regulator:

1) 866 080 requires minimum load
of 12 V (l Amp) to regulate
2) 264 870 no minimum load is required

Reduction gearbox:

with torsional shock absorber

Type „B“:

ratios available: i= 2,0 / 2,24 / 2,58 / 3,0
The gearbox i = 3,0 can be deliv
ered only installed on engine. The
max. allowed moment of inertia of
the propeller is 3000 kg cm 2

Type „C“ and “E”:

ratios available: i= 2,62 / 3,0 / 3,47 / 4,0

Max. allowed moment of inertia
of propeller:

6000 kg cm 2
Automatic high altitude adjustment
of carburetor calibration, with modified carburetor (on request)

d00374

High altitude compensator:

Effectivity: 447 UL SCDI, 503 UL DCDI, 582 UL DCDI /mod. 99

page 8 - 4
Initial issue, May 01/99

AIRCRAFT ENGINES

MAINTENANCE MANUAL

8.2.3)

582 UL DCDI and 582 UL DCDI mod.99
Description:

Engine configurations:
Bore:
Stroke:
Displacement:
compression ratio:
power output:

Torque:
Max. rpm.:
Direction of rotation:
Cylinder:
Piston:
Ignition system:

d00374

Generator output:
Ignition timing:
Spark plug:
Electrode gap:
Rotary valve:
Rotary valve timing:

Carburetor:
Fuel pump:

Two-cycle, two-cylinder-, in line rotary valve engine, mixture lubrication or by oil injection, liquid cooled,
with integrated water pump and twoway thermostat.
dual ignition, 2-carburetors
76,0 mm (2,99 in.)
64,0 mm (2.52 in.)
580,7 ccm (35,44 cu.in.)
Theoretical: 11,5 - effective: 5,75
a) 48 kW (64,4 hp SAE) at 6500 RPM;
b) 40 kW (53,6 hp SAE) at 6000 RPM;
Match propeller to achieve above
indicated full load r.p.m. as per engine version.
a) 75 Nm (55,3 ft.lb.) at 6000 RPM;
b) 68 Nm (50,1 ft.lb.) at 5500 RPM;
a) 6800 RPM.
b) 6400 RPM.
Counter-clockwise, viewed towards
p.t.o. (without reduction gearbox)
2 light alloy cylinders with cast iron
sleeve
Cast aluminium piston with 2 piston
rings
Breakerless DUCATI capacitor discharge dual ignition with magneto
generator
170W AC at 6000 RPM and 13,5 V
1,96 mm = .077 in. (18 O) BTDC
14 mm, BR8ES
0,5 mm (.02 in.)
924 200, cut-off section 132 O
Opens 130O BTDC - closes: 50O
ATDC
Measured on crankcase openings,
± 4 O tolerance
2 x BING 36, cable choke
Pneumatic fuel pump DF 52

Effectivity: 447 UL SCDI, 503 UL DCDI, 582 UL DCDI /mod. 99

page 8 - 5
Initial issue, May 01/99

AIRCRAFT ENGINES

MAINTENANCE MANUAL

Fuel:

Regular or premium gasoline, octane number not below MON 83 or
RON 90 (unleaded preferred)

Lubrication oil of engine:

1) Oil-in-fuel with Super-two stroke
oil, proposed ASTM/CEC standard
API-TC, mixing ratio 1:50 (2%)
2) By oil pump (optional) with the
same oil
Attention: pour point 10 O C below
lowest operating temperature

Lubrication oil of reduction gear:

Gear oil API-GL5 or GL6, SAE 140
EP, or 85 W-140 EP

Direction of propeller shaft:

Clockwise, viewed towards propeller flange

Starter:

Rewind starter

Standard version includes :

Engine with
- carburetors with clamps
- fuel pump
- exhaust system

Weight:

29,3 kg

(64,6 lb.)

(without: exhaust system,
carburetor, intake silencer, fuel
pump, radiator)
Optional Features
Oil pump lubrication:

The engine is lubricated by an oil
pump fitted to the engine. The
carburetor is supplied with pure
gasoline.

Intake silencer:

2) For 2-carburetor engine version
■ ATTENTION: If engine was supplied without intake silencer, the
carburetor calibration must be modified for use with intake silencer.

After-muffler:

Special after-muffler to be fitted in
addition to the exhaust muffler.

Airfilter:

l) To be fitted directly on carburetor
3) Double filter (one filter for both
carburetors)

Effectivity: 447 UL SCDI, 503 UL DCDI, 582 UL DCDI /mod. 99

page 8 - 6
Initial issue, May 01/99

d00374

2) To be fitted in the intake silencer

AIRCRAFT ENGINES

MAINTENANCE MANUAL

High altitude compensator:

Automatic high altitude adjustment
of carburetor calibration, with modified carburetor (on request)

Electric starter:

l) Rewind starter with electric starter,
p.t.o. side, for engine without gear
box,
2) Electric starter, magneto side,
without rewind starter (gearbox is
possible)

Rectifier-regulator:

1) 866 080 requires minimum load of
12 V (1 A) to regulate

d00374

2) 264 870 no minimum load is required.

Effectivity: 447 UL SCDI, 503 UL DCDI, 582 UL DCDI /mod. 99

page 8 - 7
Initial issue, May 01/99

AIRCRAFT ENGINES

MAINTENANCE MANUAL

8.3)

Components
See fig. 001, 002, and 003.
(1)

Propeller flange

(7)

Electric starter

(2)

Propeller gear box

(8)

Oil pump

(3)

Intake manifold

(9)

Electronic module(es) of ignition unit

(4)

Carburetor

(10)

Ignition housing

(5)

Water pump

(11)

Engine serial number

(6)

Exhaust manifold

(12)

Oil tank

8.3.1)

447 UL SCDI

PTO view

lateral view
Cyl. 1

4

Cyl. 2

11

3

02781

02782

fig. 001

Illustration shows 447 UL with rewind starter, intake silencer,
without gearbox.

d00374

◆ Note:

10

Effectivity: 447 UL SCDI, 503 UL DCDI, 582 UL DCDI /mod. 99

page 8 - 8
Initial issue, May 01/99

AIRCRAFT ENGINES

MAINTENANCE MANUAL

8.3.2)

503 UL DCDI

PTO view

lateral view
Cyl. 1

Cyl. 2

4

11

3
1

10
9

fig. 002

02780

2

02779

Illustration shows 503 UL DCDI with electric starter, intake silencer, and “B” type gearbox.

d00374

◆ Note:

7

Effectivity: 447 UL SCDI, 503 UL DCDI, 582 UL DCDI /mod. 99

page 8 - 9
Initial issue, May 01/99

AIRCRAFT ENGINES

MAINTENANCE MANUAL

8.3.3)

582 UL DCDI

lateral view

PTO view
Cyl. 1

Cyl. 2

12
6

9

11

1

5

8

4

2

02781

fig. 003

10
7

Illustration shows 582 UL DCDI with electric starter and “B” type
gearbox.

d00374

◆ Note:

02043

Effectivity: 447 UL SCDI, 503 UL DCDI, 582 UL DCDI /mod. 99

page 8 - 10
Initial issue, May 01/99

AIRCRAFT ENGINES

MAINTENANCE MANUAL

9) Maintenance
In this Manual the maintenance of the engines 447 UL SCDI, 503 DCDI and 582 UL DCDI
and 582 UL DCDI mod. 99 are described. The Manual is subdivided into sections and
description of function of the various systems. Some overlapping maintenance instructions
are treated as generally valid information at the beginning of this section.
The information given in the Maintenance Manual is based on data and experience which is
considered to be applicable for a skilled mechanic under normal working conditions. The
guidelines given in the Maintenance Manual are useful and necessary supplements to
training. They, however, cannot substitute competent theoretical and practical personal
instruction.
Maintenance of engines and systems requires special knowledge and special tools.
We particularly emphasize that parts and accessories not supplied as genuine ROTAX®
parts are not verified for suitability by ROTAX® and thus are not released for use. Installation
and/or use of such products may possibly change or negatively influence the design
characteristics of the engine. For damages resulting from use of non-genuine parts and
accessories ROTAX® refuses any liability.
Non-authorized modifications as well as the use of components and auxiliary components
not corresponding to the installation instructions exclude any liability of the engine manufacturer.
Besides our instructions in the documentation supplied, also respect the generally valid
safety and accident preventive directives and legal regulations.

9.1)

General proceeding instructions
When carrying out maintenance and service work, respect without fail the safety
regulations. At maintenance of cooling, lubricating and fuel system take care without
fail that no contamination, metal chips, foreign material and/or dirt enters the system.
Use only mallet (plastic or rubber) for dis- and re-assembly of parts.
Never loosen or tighten screws and nuts with pliers but only with the specified tools.
Before each reassembly check assembled components for missing parts. Only use
the adhesives, lubricating, cleaning agents and solvents indicated in the maintenance
instructions. If not respected, damage may be the consequence.
Exactly observe the tightening torques for screws and nuts. Overstretching or too
loose tightening may cause severe engine damage.
Before re-using parts disassembled, clean, check and refit them per instructions.

9.2)

Trouble shooting
In the Operator’s Manual there is a list of possible failures as well as indication of
possible remedy. For details refer to the Repair Manual 462-532-582.

d00375

See current Operator’s Manual for engine types 447 UL SCDI, 503 DCDI, 582 UL
DCDI mod. 99.

Effectivity: 447 UL SCDI, 503 UL DCDI, 582 UL DCDI /mod. 99

page 9 - 1
Initial issue, May 01/99

AIRCRAFT ENGINES

MAINTENANCE MANUAL

9.3)

Basic information
To warrant correct servicing of the engine, the use of genuine parts is required. Use
of special tools, devices and lubricating media is necessary.
▲ WARNING:

Only qualified personnel trained especially for this engine are
allowed to carry out the maintenance and service work.

Only use clean screws and nuts. Check the contact faces and threads for damages.
In case of doubt, use new screws and nuts.
Always replace self-locking nuts once removed.
Respect without fail the tightening torques indicated in the respective table.
Replace all sealing rings, gaskets, lock washers, O-rings and oil seals at engine
re-assembly.

9.4)

Auxiliary tools
See fig. 004.
Screwdriver ground to shape for piston pin circlip removal

–

Compression tracer and 2 pressure gauges, adapter for
dial gauge in spark plug thread

–

Stud extraction tool

–

Scraper, lapping fleece, grinding wheel, cover
sheet, adhesive tape

–

Cleaning agent, approved cleaners, funnel,
graphite marker.

Measuring tools

fig. 004
Vernier callipers,
00141
Dial gauge,
Micrometer, internal micrometer,
Feeler gauge,
Stroboscope:
Supply voltage 8 - 15 V. Flash triggering by inductive pick-up.
Multimeter:

Electronic, 3 1/2 digits indication.
Current range 10 A.
Direct voltage range 200 V minimum.
Resistance range 200 W ÷ 2 MW
Acoustic continuity tester.

Oscilloscope:

2 channels
Analogous
Sensitivity 5 mV to 5V/div
Frequency limit 50 MHz

▲ WARNING:

Using these instruments, observe the manufacturer's specifications.

Effectivity: 447 UL SCDI, 503 UL DCDI, 582 UL DCDI /mod. 99

page 9 - 2
Initial issue, May 01/99

d00375

9.5)

–

AIRCRAFT ENGINES

MAINTENANCE MANUAL

9.6)

Special tools and devices
For the special tools required, refer to the current engine, illustrated parts catalog.

9.7)

Consumable materials
9.7.1)

Two stroke oil
In principle motor oil is used for lubrication of components during reassembly, except where specified otherwise. Use only oils specified in the
"Lubricant Chart" in order to avoid chemical reaction.

9.7.2)

Lithium grease
Is used on all electrical connections, to avoid leakage current. After
assembly is complete, apply Lithium grease to the connection as anticorrosive.

9.7.3)

Multi-purpose grease LZ
Generally usable, neutrally coloured multipurpose grease, water resistant
and highly adherent. Usable for temperatures from -35°C to +120°C (-31°F
to 248° F). The grease resists to mechanical load.

9.7.4)

Corrosion inhibiting oil MOBILARMA 524
Corrosion inhibiting oil, unsoluble in water, hydrocarbon basis with additives. The pour point is below -18° C ( -3° F).
▲ WARNING:

9.7.5)

When handling chemicals, respect the generally valid
safety directives.

Grease MOLYKOTE G-N
Is used on highly loaded bearing positions as initial lubrication and at press
fits for prevention of fretting corrosion. MOLYKOTE is applied to both
components mated. It is especially mentioned where to use it.

9.7.6)

LOCTITE Anti-Seize 76710
High-temperature lubricating and anti-corrosion agent. LOCTITE AntiSeize is always applied on both components mated and warrants for
maintenance-free bearing seats due to the hermetically sealed sliding
surface.

9.7.7)

SILASTIC

d00375

Is used for vibration damping of the exhaust system springs.Run a bead
of silastic from one end to the other of the springs.

Effectivity: 447 UL SCDI, 503 UL DCDI, 582 UL DCDI /mod. 99

page 9 - 3
Initial issue, May 01/99

AIRCRAFT ENGINES

MAINTENANCE MANUAL

9.7.8)

LOCTITE "574 orange"
Is a sealing material used as an alternative to conventional solid gaskets
where a high friction factor and exactly defined distance between parts is
required. LOCTITE sealing compound is a solvent-free liquid gasket
applied to the sealing surfaces. After assembly it cures under hermetical
conditions with metal contact within several hours. This gives a sealing
completely adapted to the surface structure of the parts to be sealed.
Its surface sealing properties are guaranteed for temperature range
between - 55°C and + 200°C (- 67°F to + 390°F). No corrosion is possible
in the sealing gap.

9.7.9)

LOCTITE "648 green"
Heavy duty adhesive or screw securing agent. Its cure time depending on
the materials and temperatures is max. 12 hours and it resists temperatures from -55° C (- 67°F) up to +175° C (347° F). To separate parts
secured by this agent, it may be necessary to heat the parts to approx.
250° C (480° F).

9.7.10)

LOCTITE "221 violet"
Medium duty adhesive or screw securing agent suitable for materials of
different properties. In case of strain the stress is distributed evenly over
the whole surface of connection. The adhesive connection creates hermetic sealing for gas and liquids. This sealing property protects the parts
from corrosion.
LOCTITE 221 is suitable for screws and nuts up to M12 threads and for low
duty connections.

9.7.11)

MICRONORM shot blasting abrasive
This abrasive is suitable for local and gradual very fine treatment of steel
parts with rust film (propeller shaft). The MICRONORM shot blasting
abrasive does not contain any noxious matter, is approved by the competent authorities and warrants for optimum cleaning. The granulates used
are of sizes 40 to 60 µ. The surface roughness to be achieved is 0,5 - 1 µ
representing a microfinish of the parts.

9.7.12)

Lapping fleece SR 4600 A - very fine grading

d00375

Is sold by the meter and used for manual removal of smaller rust spots or
oxidation, especially for optimum ground connections. It is most appropriate for removal of LOCTITE from surfaces or threads to make them
metallic clean. Before reapplying LOCTITE, clean surfaces with nitrothinner or degreasing agent (CASTROL ZA 30 or OMV - SOFT SOL).
When using solvents, mind the safety regulations for persons and environments.

Effectivity: 447 UL SCDI, 503 UL DCDI, 582 UL DCDI /mod. 99

page 9 - 4
Initial issue, May 01/99

AIRCRAFT ENGINES

MAINTENANCE MANUAL

9.7.13)

Cleaning agents
▲ WARNING:

Use only approved cleaning agents (e.g. fuel, varsol,
etc.) for cleaning metal parts.

Do not use cold cleaner on lye base degreasing agents. Do not clean
coolant- and oil hoses with aggressive solutions. Clean off remains of
sealing compound with sealant remover.
Soak combustion chamber, piston and cylinder head with cleaning agent
and remove combustion residues with a bronze brush. Very good results
were achieved with CASTROL "Clenvex 2000" as a cold cleaning agent
on a basis of laboratory fuel and kerosine. It is a solvent - cold cleaner, free
of halogen, on base of selected fuel fractions, and it is biologically
disposable.
Never use caustic or corrosive cleaning agents.
▲ WARNING:

9.8)

Proceed with great caution when using solvents. Inhaling of vapours is hazardous to health. Always dispose of
solvent as per environmental regulations.

Securing elements
■ ATTENTION: Self-locking nuts, cotter pins, tab washers and safety wires must
be replaced each time they have been removed.
Respect without fail all additional indications regarding securing and sealing means
and lubrication of fixation elements. Adhere to specified tightening torques.
■ NOTE:

Fit the lock washers with the bent up ends (1) facing the screw head
or nut.

00144

1

d00375

fig. 005

Effectivity: 447 UL SCDI, 503 UL DCDI, 582 UL DCDI /mod. 99

page 9 - 5
Initial issue, May 01/99

AIRCRAFT ENGINES

MAINTENANCE MANUAL

9.8.1)

Safety wiring
See fig. 006 and 007.
Safety wiring serves to secure screws or nuts to prevent unintended
loosening. The screws or nuts are secured by a 0,8 mm (.0315 in.) safety
wire twisted 3 to 4 turns per 10 mm (.4 in.). The wire must by no means be
overstretched.

fig. 006

Pass through
safety wire

Wind wire end around Twist wire several times Pass wire through and
the screw
up to next screw
stretch it with pliers

00145

FINAL CHECK
Safety wiring between screws must
not be loose!

Twist wire around the Stretch wires and Turn twisted wire end Cut off excess Bend wire end and
twist approx. 4 times
screw
length of wire
around screw
press it towards
screw

▲ WARNING:

As a principle, all external engine components and
accessories must be wire-secured for safety reasons.

Various typical applications of safety wiring

fig. 007
Effectivity: 447 UL SCDI, 503 UL DCDI, 582 UL DCDI /mod. 99

page 9 - 6
Initial issue, May 01/99

d00375

00146

AIRCRAFT ENGINES

MAINTENANCE MANUAL

9.8.2)

Nut securing

d00375

When using a self-locking nut, take care that the polyamide insert ring on
nuts according to DIN 985 as well as the securing element on nuts
according to DIN 980 is positioned towards outside.

Effectivity: 447 UL SCDI, 503 UL DCDI, 582 UL DCDI /mod. 99

page 9 - 7
Initial issue, May 01/99

AIRCRAFT ENGINES

MAINTENANCE MANUAL

9.10) Treatment of corrosion and surface damages
At longer standstill it may occur that a rust film forms on various metal parts. With
considerable corrosion or heavily corroded screws, nuts, shims, bearings, bushes
etc., an exchange is inevitable.

Propeller shaft
The flange of the propeller shaft is likely to get a rust film. A special treatment is only
possible with propeller shaft removed. After covering all bearing seats with plastic
adhesive or a plastic tube, the propeller flange can be treated with MICRONORM shot
blasting abrasive with incorporated anticorrosive.
At heavy rust damage, when the material is affected, renewal of the propeller shaft
is necessary.

Electric system
Formation of a rust film on the permanent magnets in the magneto flywheel and on the
metal cores of the pick-ups is harmless. Replace screws and lock washers at heavy
oxidation or rust formation. Before reassembly clean all contact surfaces of the
screws removed and apply LITHIUM grease. Take care that no foreign material falls
into the magneto flywheel. Clean cable shoes and apply LITHIUM grease to the
contact surfaces to assure lasting contact.
Check contact between plugs and/or fasten connections by separation test, if
necessary apply contact spray to increase conductivity.

9.11) Engine preservation and engine back to operation

d00375

Refer to current Operators Manual 447 UL SCDI- 503 UL DCDI- 582 UL DCDI
mod.99.

Effectivity: 447 UL SCDI, 503 UL DCDI, 582 UL DCDI /mod. 99

page 9 - 8
Initial issue, May 01/99

AIRCRAFT ENGINES

MAINTENANCE MANUAL

10) Maintenance Checks
▲ WARNING:

Work on the engine is only allowed to be carried out by experienced two
stroke mechanics. See Chapter 9.3).

The scheduled maintenance checks consist of the following groups:

10.1) Periodical maintenance
Time-related checks
These are checks prescribed after reaching defined hours of operation, to avoid
engine troubles by preventive maintenance. A description of work to be carried out
at specific time intervals is defined in the “MAINTENANCE SCHEDULE“.

Seasonal checks

d00376

All rubber parts like hoses, rubber dampers, rubber coupling, carburetor socket etc.
must be renewed every five years or as required by condition.

Effectivity: 447 UL SCDI, 503 UL DCDI, 582 UL DCDI /mod. 99

page 10 - 1
Initial issue, May 01/99

AIRCRAFT ENGINES

MAINTENANCE MANUAL

10.2) Maintenance Schedule

300 h

275 h

250 h

225 h

200 h

175 h

150 h

125 h

75 h

100 h

50 h

10 h

12,5 h

25 h

X

X

X

X

X

X
X

X
X

X
X

X
X

X
X

X
X

X
X

X
X

X
X

X
X

X
X
X
X
X

X
X

X
X

X
X
X
X
X

X
X

X
X

X
X
X
X
X

X
X

X
X

X
X

X
X

X
X

X

X
X

X
X

X
X

X

X
X

X
X

X
X

X
X

X
X

X

X
X

X

X

X
X

X

11.19

X

X

X

X

11.23

X

X

X

11.19
11.20
11.21
11.22
11.22

X
X

X

X
X
X
X
X

X
X
X

X

X

X

X
X
X 6)
X 6)

X
X
X
X 6)
X 6)

X
X
X
X

X
X
X 6)
X 6)

X
X
X
X

11.24
11.25
11.26
11.27
11.28

X 6)

X 6)

X

X 6)

X

11.28

X 6)
X 6)

X 6)
X 6)

X
X

X 6)
X 6)

X
X

11.29
11.29

X 6)

X 6)

X

X 6)

X

11.30

X

11.31

X

11.32

1) and after every replacement of gasket(s)

11.33

300 h

275 h

250 h

X

225 h

Checks and work

X

200 h

38

X

175 h

37

X

150 h

36

X

X

125 h

35

X

X

75 h

33
34

X

X
X

100 h

32

X

X

50 h

27
28
29
30
31

X
X

chapter signature
11.1
11.2
11.3
11.4
11.5
11.6
11.7
11.8
11.9
11.10
11.11
11.12
11.13
11.14
11.15
11.16
11.17
11.18
11.18

X

25 h

26

X
X
X

10 h

21
22
23
24
25

X

12,5 h

20

Ground run
Level check of liquids
Retorque cylinder head nuts 1)
Retorque exhaust manifold screw s 1)
Check rew ind starter rope 10)
Check electric starter gear
Inspect spark plugs 10)
Replace spark plugs
Check ignition system
Check and clean inside spark plug caps 10)
Checking of V- belt tension
Lubricate ball joints
Replace exhaust muffler springs
Lubricate control cables 3)
Check propeller balance and tracking 2,3)
Inspect propeller mounting bolts 3)
Clean and oil air filter
Check fuel filter
Replace fuel f ilter
Check carburetor(s) and re-adjust (idle speed,
cable tension, ...)
Clean carburetor(s) and check for w ear
Replace jet needle and needle jet
Check fuel pump (measure fuel pressure)
Check gearbox oil level
Replace gearbox oil
Check and adjust gearbox, preload of springs
(type B gearbox)
Replace rotary valve lubrication oil
Inspect cylinder head and piston crow n 4)
Inspect piston rings for f ree movement 5)
Check piston diameter 7)
Piston ring: check gap 7,11)
Piston ring: check axial clearance (rectang.
Ring) 8,12)
Check cylinder diameter 7,11)
Cylinder: check for roundness 7,11)
Replace cylinder head-, cylinder base- and
exhaust-gasket 8)
Inspect piston pin and bearing
Inspect crankshaft and replace outer seals if
necessary
General overhaul of engine 9)

2h

Checks and work
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19

2h

The following maintenance is planned and necessary for ROTAX 447 UL SCDI, 503
UL DCDI, 582 UL DCDI and 582 UL DCDI mod. 99:

02948

8) If cylinder has been dismantled

9) To be carried out every five years or
every 300 hours whichever comes first.
3) according to instructions of manufacturer
contact authorized distributor or service
4) if carbon layer is more than 0,5 mm thick, decarbonize
center.
2) also after any damage

6) if used in very dusty atmosphere
7) wear limit see Service Information 5 UL 91

10) To be examined after every 12,5 hours
of operation.
11 Necessary only if piston rings are not
freely moving

Effectivity: 447 UL SCDI, 503 UL DCDI, 582 UL DCDI /mod. 99

page 10 - 2
Initial issue, May 01/99

d00376

5) if piston ring sticks clean and replace if necessary

AIRCRAFT ENGINES

MAINTENANCE MANUAL

11) Maintenance of the various systems:
11.1) Ground test
Check smooth engine run. Furthermore verify take-off RPM of engine and compliance with all limits.

11.2) Level check of liquids
Verify capacity of all operation liquids.
Such as:
Fuel capacity
Oil quantity for rotary valve drive (on engine 582 only)
Oil level in gearbox (see section 11.22)
Oil level for oil injection lubrication

d00377

Coolant level (on engine 582 only)

Effectivity: 447 UL SCDI, 503 UL DCDI, 582 UL DCDI /mod. 99

page 11 - 1
Initial issue, May 01/99

AIRCRAFT ENGINES

MAINTENANCE MANUAL

11.3) Retorque cylinder head nuts (only on 447 UL SCDI and 503 UL DCDI)
▲ WARNING:Engine must be cool for retorquing procedure of cylinder head nuts.
◆ NOTE:

Consider both cylinders as one unit because they are joined by
exhaust and intake manifolds. Use a cross sequence for tightening the
nuts, starting from the center. Ensure that cowl screws are torqued
less than the head nuts.

Diagram for torquing sequence when
manifolds are in place
Tightening torque:

22 Nm (195 in.lb.)

02884

fig. 008

11.4) Retorque of exhaust manifold screws:
The screws of the exhaust manifold must be retightened to the specified torque.
Tightening torque for 503 UL DCDI and 582 UL DCDI: 22 Nm (195 in lb)
Tightening torque for 447 UL SCDI: 25 Nm (221 in lb)

fig. 009
02885

11.5) Checking of the rewind starter rope
Check starter rope condition according to maintenance schedule. Replace when worn or frayed.

d00377

To change the starter rope, follow the procedure
outlined (the numbers stated in brackets refer to the illustration).

Effectivity: 447 UL SCDI, 503 UL DCDI, 582 UL DCDI /mod. 99

page 11 - 2
Initial issue, May 01/99

AIRCRAFT ENGINES

MAINTENANCE MANUAL

11.5.1)

Rewind starter dismantling:
First remove the rewind starter assembly from the engine.
Second, remove the snap ring (9), loop spring (8), circlip (7), pawl lock (6),
and the pawl (5).
Pull out the starter rope fully to the end, hold starter housing (1) and rope
sheave (3) together In their position. There is an opening in the rope
sheave. The key clamp
(4) visible in the opening
must be pushed out in
the opposite sense of
the pulling direction. Pull
the rope out of the rope
sheave.
fig. 010

11.5.2)

Rewind starter reassembly:

02939

Insert the new starter
rope into the rope
sheave, fit the key clamp
in the same position as it
was before and refit the parts (5), (6),
(7), (8) and (9).
▲ WARNING: Do not remove spring container (2), this might cause
injuries.
Do not operate the engine if the rewind starter is defective.
Most starter problems are due to improper handling.

11.6) Check electric starter gear
Inspect teeth and check free- wheeling of overrun clutch. Ensure neat fit of stop collar
and circlip and proper shape of spring.
Check free movement of pinion on the coarse thread.
◆ NOTE:

For further details see current Repair Manual 462-532-582.

11.7) Inspection of spark plugs
Due to varying fuel properties etc., check according to maintenance schedule.
Replace as required or annually: Provided that spark plug heat range and the
carburetor calibration are correct, the spark plugs will have a brownish tinge at the
electrodes of both spark plugs after full load operation.

d00377

On engines with single carburetor, one sooty spark plug usually indicates a bad plug
or faulty ignition system. If both plugs are sooty with oil deposits, carburation and air
system should be checked. On engines with two carburetors you should switch the
carburetor to trace the problem.
■ ATTENTION:

Do not switch the carburetors on 618 UL DCDI because the
jetting is different.

Effectivity: 447 UL SCDI, 503 UL DCDI, 582 UL DCDI /mod. 99

page 11 - 3
Initial issue, May 01/99

AIRCRAFT ENGINES

MAINTENANCE MANUAL

■ ATTENTION:

Always change both plugs. Never interchange plugs from one
cylinder to the other.

If both plugs have "white" electrodes with "melt" droplets, first suspect lean mixture.
If calibration is correct and there is no evidence of manifold leaks, lack of fuel, or
incorrect float settings, don't change the plugs to a colder range. Check if cooling
system is operating correctly.
■ ATTENTION:

Heavy oil deposits on the electrodes and insulator may cause
engine problems, exchange regularly according to maintenance
schedule, or at any indications of trouble.

If, after cleaning or changing the spark plugs, you still have an ignition problem, check
to see if only one cylinder is affected or both. Some thought to what is common to both
systems or only one will isolate the problem more efficiently. If no external fault is
found, the ignition unit must be checked.
■ ATTENTION:

Never clean spark plugs with an abrasive cleaner.

Remember to correctly gap your plugs with a wire gauge (see technical data, section
8.2). Spark plugs must be torqued (see section 11.7). If problems occur too
frequently, cause must be determined and rectified.

fig. 011
overheated

normal

fouled

(light gray)

(brownish)

(black)

02790

02791

02792

11.8) Replacement of spark plugs
The following type of spark plugs may be used at renewal of the spark plugs:
fig. 012
◆ NOTE:
The resistance spark plug can be distinguished by the part
no. and by the designation. Tightening torque: 27 Nm (238
in lb) only on cold engine.
part no.

spark plug designation

897 050

spark plug without resistance

B8ES

897 055

spark plug with resistance

BR8ES

◆ NOTE:

The "R" in the designation denotes the resistance of approx.
5 kW, which results in better R.F.I. suppression.

Effectivity: 447 UL SCDI, 503 UL DCDI, 582 UL DCDI /mod. 99

BR8ES

page 11 - 4
Initial issue, May 01/99

d00377

01155

AIRCRAFT ENGINES

MAINTENANCE MANUAL

11.9) Check of the ignition system
Verify all electrical connections for good contact and ensure they are free of corrosion.
Inspect the wiring for wear, damage and corrosion.
Before flight the function of the two ignition circuits (on 503 and 582) must be checked.
For checking the ignition unit the engine must be operated at 3000 to 3500 1/min and
alternately ignition circuit 1 and 2 must be switched off. The RPM-drop must not
exceed max. 300 1/min.

11.10) Check and clean inside of spark plug connectors
Inspect spark plug connector for cracks, burn-off, dampness and fouling. Check
connection with ignition cable and fitting of rain protection cover. The resistance value
of the standard spark plug connector is 4,5 ÷ 5,5 kW.
fig. 013
For various applications radio interference suppression plug connectors must be used according to
respective regulations. These are more prone to troubles than the standard resistor type connector, due to
the metal shielding.
Resistance of these connectors is 0,8 ÷ 1,2 kW.
Never pull off spark plug connector on a running
engine.

02890

Clean contact surfaces in the spark plug connectors as required.

d00377

■ ATTENTION: On engine installation with spark plugs down, it is highly recommended to additionally secure spark plug caps.

Effectivity: 447 UL SCDI, 503 UL DCDI, 582 UL DCDI /mod. 99

page 11 - 5
Initial issue, May 01/99

AIRCRAFT ENGINES

MAINTENANCE MANUAL

11.11) Checking of V - belt tension (only on fan cooled 447
and 503 engines)
V - belt deflection
Replace belt if frayed or if it can no longer be tensioned
to specification.
The tension of the V-belt can be adjusted by shims
between the V-belt pulley half and the fan (resp. the
protection sheave on 503). The V-belt is correctly
tensioned when it can be depressed 9 - 10 mm (.35 ÷ .39
in.) to indicated force "F" (in the middle between the 2 Vbelt sheaves).

11.12) Lubricate Ball joints

9 - 10 mm
35 - 39 in.

F
F = 50 N
F= 11 lbf

fig. 014

Check exhaust system prior to every flight for tightness,
physical damage or changes in sound pattern. Especially inspect springs and hooks.

02891

The muffler has to be supported on vibration damping
blocks. All ball joints have to be greased regularly with heat resistant lubricant (e.g.
LOCTITE Anti-Seize, 297 434) to avoid gripping or seizing of joints and consequent
breaking of exhaust components.

11.13) Replace exhaust muffler springs
The muffler must be suspended on engine and frame and also be secured against
loss without squeezing the ball joints.
Secure the muffler springs by wire against loss. The sketch illustrates a possibility
how to interconnect the exhaust springs to prevent the vibration of these springs and
thus pre-mature wear.

fig. 015

d00377

02895

Effectivity: 447 UL SCDI, 503 UL DCDI, 582 UL DCDI /mod. 99

page 11 - 6
Initial issue, May 01/99

AIRCRAFT ENGINES

MAINTENANCE MANUAL

11.14) Lubricate control cables
Verify and lubricate all control cables in accordance with maintenance schedule of the
aircraft builder.
◆ NOTE:

Observe oil specification of the aircraft builder.

11.15) Check propeller balance and tracking
A new propeller must be balanced to better than 1gm to avoid vibration problems and
overstressing of the drive system. Used propellers may be max. 2,5 gm out of
balance.

11.16) Inspect propeller mounting bolts
Proceed according to propeller manufacturer instructions.

11.17) Clean and oil air filter
11.17.1)

Application of new air filters:

For a higher life-span and optimal engine protection the
filter corrugations have to be moisturized with oil. Unoiled
filters lose their effectiveness against dirt and dust.
Every corrugation of the filter has to be sprayed with oil.
After 5 - 10 minutes the filter mat will be soaked with oil,
noticeable on the uniform red colouring.
Never use gear oil, diesel, 2-stroke oil or motor oil as they
attract water.
If necessary, apply filter grease on sealing face, but don’t
grease clamp connection of filter.
02892

d00377

fig. 016

Effectivity: 447 UL SCDI, 503 UL DCDI, 582 UL DCDI /mod. 99

page 11 - 7
Initial issue, May 01/99

AIRCRAFT ENGINES

MAINTENANCE MANUAL

11.17.2)

Cleaning of used air filters:
First, lightly tap off surface dirt and wet with cold
water. Roll filter in filter cleaning and degreasing
fluid.
Never use gasoline, steam, caustic liquids, detergents or high pressure cleaning.
The level of the cleaning fluid should be approx.
3/4 of the height of corrugations. Dirty fluid must
not run inside of filter. Allow at least 5 minutes to
dissolve the dirt.
02894

fig. 017
02893

After that, rinse
fig. 018
filter with cold
water from inside to outside.
Shake off and let it dry in free
air. Don’t dry with compressed
air, over naked flame or with hot air fan.
Prior to installation, service filter with oil
(see previous chapter).
Filter due for renewal depends on
enviromental conditions, but at the latest after
300 hours of operation.

11.18)

Check and replacement of fuel filter
The flow through the filter may be restricted due to the long term build up
of dirt. A more serious type of blockage, which can occur quite rapidly is
caused by a reaction between detergents in certain two-stroke oils and
water in the fuel.
Both types of blockage may be difficult to detect visually. If blockage is
suspected, renew fuel filter or filter element. Subsequently avoid water
contamination of fuel.

11.19)

Clean carburetors and check for wear
-

Stop engine at raised speed and verify float level.

-

Inspect carburetor assy. for leakage.

-

Check float valve for easy operation.

-

Inspect clip of jet needle for wear.

-

Inspect sieve sleeve.

-

Clean the carburetor with fuel as required.

◆ NOTE:

For further details see also current Repair Manual 462532-582

Effectivity: 447 UL SCDI, 503 UL DCDI, 582 UL DCDI /mod. 99

page 11 - 8
Initial issue, May 01/99

d00377

Attend to the following:

AIRCRAFT ENGINES

MAINTENANCE MANUAL

11.20)

Replace jet needle and needle jet
The needle jet and jet needle must only be exchanged by a mechanic with
experience on two-stroke engines and in accordance with the relevant
Repair Manual 462-532-582, section carburetor.

11.21)

11.22)

Clean and check fuel pump
-

Inspect the fuel pump.

-

Verify the fuel pressure: 0,2 - 0,5 bar (3 - 7 p.s.i).

Check gearbox oil level, replace gearbox oil
For draining the oil, remove magneto drain plug.
Replenish oil, until oil emerges at the respective lower oil level plug.
■ ATTENTION:

The two large ventilation bores on both sides have to
remain always open to warrant dissipation of heat at
gearbox type C and E.

Wire-secure vent screw, oil level plugs and drain plugs.
◆ NOTE:

Illustration shows “B” type gearbox

fig. 019
02998

d00377

For oil quality see technical data

Effectivity: 447 UL SCDI, 503 UL DCDI, 582 UL DCDI /mod. 99

page 11 - 9
Initial issue, May 01/99

AIRCRAFT ENGINES

MAINTENANCE MANUAL

position of installation* B
SZ
330 cm3
SS
300 cm3

gearbox type
C/CL
E/EL
200 cm3
400 cm3
120 cm3
180 cm3
02978

* refer to latest revision of the current installation manual.

11.23)

Checking and adjusting of gearbox, preload of springs
(B- type gearbox)
Place gearbox on a suitable support under hand press. Place the mounting
yoke, part no. 876 880 on the dog gear (20) (see “disassembly and
judgement”). Place angular ring (22) upside down (with “L” shape downwards (see ill.) on prop shaft to facilitate reading of the distance A. Apply
a load of 16 kN (3600 lbs) on the dog gear via the mounting yoke. With this
load, disk springs will be completely compressed.
■ ATTENTION: Do not exceed maximum load of 16 kN (3600 lbs),
otherwise cover or dog gear will be damadged.
With springs in compressed state, measure A, the distance from top side
of angular ring to lower edge of groove (see illustration). Relieve pressure,
remove all items from prop shaft and compensate distance A, by placing
appropriate shims (16) under distance ring (17). Shims are available as
spare parts in the sizes 0,1 / 0,2 / 0,3 / 0,5 and 1,0 mm.
RELIEVED

LOADED

02899

fig. 021

02896

fig. 022

02895
d00377

fig. 020

Effectivity: 447 UL SCDI, 503 UL DCDI, 582 UL DCDI /mod. 99

page 11 - 10
Initial issue, May 01/99

AIRCRAFT ENGINES

MAINTENANCE MANUAL

11.24)

Renewing of the rotary valve lubrication oil (582 UL DCDI /mod.
99 only)
Drain oil completely. For complete emptying, the engine must be inclined.
Afterwards refill the oil tank. Allow some time for settling. Crank the engine
by hand several times to vent the system.
Fill tank to max. mark and after a short trail run verify the oil level again.

11.25)

Inspection of the cylinder head and piston crown
Remove the cylinder head as per the current and relevant Repair Manual.
Deposits on combustion chamber in cylinder head and on piston crown
must not exceed 0,5 mm (0,02 in).
Excessive deposits must be removed carefully with lapping fleece.
▲ WARNING:

11.26)

Clean the pistons not installed in the engine but on the
bench, to prevent carbon deposits ending up in the
engine.

Inspection of the piston rings
Remove cylinder head and cylinder as per the current and relevant Repair
Manual.
Verify easy movement of the piston rings. A sticking ring must be removed,
use piston ring pliers when replacing rings.
If several rings have to be removed ensure assignment to the respective
piston.
Clean removed piston rings and renew as required.

d00377

Never overstress piston ring as the ring would lose its pretension and the
molybdenum coating might break off.

Effectivity: 447 UL SCDI, 503 UL DCDI, 582 UL DCDI /mod. 99

page 11 - 11
Initial issue, May 01/99

AIRCRAFT ENGINES

MAINTENANCE MANUAL

11.27)

Check piston diameter
The dimension of the pistons must be in the range as stated in the table
below.

Engine
Type

ROTAX
part. No.

447 UL
503 UL
582 UL

886050
996245
888590

Notes:

Stamped on
piston crown
67,45
71,93
75,94

Nominal
2) Height H
Diameter DN ± Oversizes
1)
available
[mm]
0,005 mm

67,46 67,445 67,455
71,94 71,925 71,935
75,95 75,935 75,945

2
2
2

20,8
18
20,5

piston to
wall
clearence
[mm]
new
0,05-0,07
0,07-0,09
0,06-0,08

piston to
wall
clearence
[mm]
Wear Limit
0,15
0,2
0,15

1) Dimensions H = Height for measurement of the nominal diameter on new piston
perpendicular to the center axis of the piston pin. For used pistons measuring the
__biggest diameter is also valid.
2) Please find nominal value of oversize pistons in the respective parts list.

03125

fig. 023

d00377

02950

Effectivity: 447 UL SCDI, 503 UL DCDI, 582 UL DCDI /mod. 99

page 11 - 12
Initial issue, May 01/99

AIRCRAFT ENGINES

MAINTENANCE MANUAL

11.28)

Piston ring, checking of gap and axial play
Remove piston rings, using piston ring pliers. Never overtension rings,
otherwise ring loses its pretension, and Molybdenum coating will break off.
Ensure to refit used piston rings into same location and position as before
removal. A new rectangular ring may be fitted either way up.

fig. 025
02898
02897

A

fig. 024

Piston rings are checked for end gap and flank clearance. With ring fitted,
clearance of flank can be checked by feeler gauge.
To measure the end gap "A" of a piston ring, position ring in a new cylinder
using piston as pusher and check gap by feeler gauge. To check the end
gap on a used ring for wear limit, position ring in the corresponding cylinder.
1st ring
Dimension

wear limit mm

(in.)

ring gap ................................................................ 1mm .........................0,039
ring clearence ....................................................... 0,2 mm ..................... 0,008

2nd ring

d00377

Will be renewed when the 1st ring is replaced.

Effectivity: 447 UL SCDI, 503 UL DCDI, 582 UL DCDI /mod. 99

page 11 - 13
Initial issue, May 01/99

AIRCRAFT ENGINES

MAINTENANCE MANUAL

11.29)

Checking of cylinder diameter and roundness
Cylinders are machined to 2 tolerance groups, marked on the spigot either red
or green. The difference in bore dia. is 0,01 mm. Suitable pistons are available
in the same colour code.
Dimension

new mm

(in.)

out of round .......... 0,00 ÷ 0,02
conicity ................. 0,00 ÷ 0,03
(0,0032)

Dimension
(in.)

wear limit mm (in.)

(0,00÷ 0,0008) .................... 0,05 (0,002)
(0,00÷ 0,0012) .................... 0,08

new mm

(in.)

wear limit mm

Type 447 UL
Cylinder standard red .......... 67,50 ÷ 67,51 (2,6575 ÷2,6579) .............67,59(2,66)
Cylinder standard green ....... 67,51 ÷ 67,52 (2,6579 ÷2,6583) ............. 67,60(2,661)
Cylinder (1st oversize, red) ... 67,78 ÷ 67,79 (2,8444 ÷2,8448) ...........67,87(2,848)
Cylinder (1st oversize, green) 67,79 ÷ 67,80 (2,8448 ÷ 2,8452)67,88 . (2,848)
Cylinder (2nd oversize, red) ... 68,00 ÷68,01 (2,8543÷2,8547)68,09 ... (2,858)
Cylinder (2nd oversize, green) 68,01 ÷ 68,02 (2,8547÷2,8551)68,10 ... (2,858)
Type 503 UL
(standard, red) ...................... 72,00
(2,8385)
Cylinder (standard, green) .... 72,01
Cylinder (1st oversize, red) .... 72,25
Cylinder (1st oversize, green) 72,26
Cylinder (2nd oversize, red) ... 72,50
Cylinder (2nd oversize, green) 72,51
Type 582 UL
Cylinder (standard, red)
76,01
Cylinder (standard, green)
76,02
Cylinder (1st oversize, red) 76,26
Cylinder (1st oversize, green) 76,27
Cylinder (2nd oversize, red) 76,51
Cylinder (2nd oversize, green) 76,52

◆ NOTE:

÷ 72,01

(2,835 ÷ 2,836) ........... 72,10

÷ 72,02 (2,8350÷2,8354)72,10 ... (2,8385)
÷72,26 (2,8444÷2,8448)72,35 ... (2,848)
÷ 72,27 (2,8448 ÷ 2,8452)72,35 . (2,848)
÷72,51 (2,8543÷2,8547)72,60 ... (2,858)
÷ 72,52 (2,8547÷2,8551)72,60 ... (2,858)
÷ 76,02
÷ 76,03
÷ 76,27
÷76,28
÷ 76,52
÷76,53

(2,9925÷
(2,9929÷
(3,0023÷
(3,0027÷
(3,0122÷
(3,0123÷

2,9929)76,10
2,9933)76,10
3,0027)76,35
3,0031)76,35
3,0129)76,60
3,013)76,60

(2,996)
(2,996)
(3,006)
(3,006)
(3,016)
(3,016)

Diameter readings are taken in crankshaft axis and 90°
across.
c. 5 mm (.2 in.) below top
of cylinder

fig. 026

c. 5 mm (.2 in.) above
exhaust port

d00377

c. 5 mm (.2 in.) above
spigot cut-away

02937

Effectivity: 447 UL SCDI, 503 UL DCDI, 582 UL DCDI /mod. 99

page 11 - 14
Initial issue, May 01/99

AIRCRAFT ENGINES

MAINTENANCE MANUAL

11.30)

Replace cylinder head-, cylinder base- and exhaust gaskets
◆ NOTE: Necessary only if cylinders have been removed.

11.31)

Inspect pins and bearings
11.31.1)

Piston pin:
Check piston pin for wear and pitting at bearing contact surface
and take diameter readings.

Dimension

new mm

Piston pin ................ 17,997÷ 18,0

(in.)

(0,7085 ÷ 0,709) ................. 17,97 (0,707)

■ ATTENTION:

fig. 027

02941

wear limit mm (in.)

Renew piston pin at detection of
perceptible traces of wear, even if
dimensions are correct, at begin
nings of pitting or discoloration. Al
ways renew piston pin circlips af
ter every removal.

11.31.2) Piston pin bearing:
The needle cage has been superseded by a cageless
needle bearing, increasing life-span essentially due to
higher load capacity. The cageless needle bearing is a
needle bearing with 31 needles and 2 thrust washers.
On engine 582 UL this needle bearing has been fitted
since the beginning of serial production.
◆ NOTE: It is strongly advised to fit the cageless piston
pin bearing (part no. 832 320) at engine repair.

d00377

Inspect needles for wear and pitting. With one needle
visibly damaged, renew all 31 needles.

Effectivity: 447 UL SCDI, 503 UL DCDI, 582 UL DCDI /mod. 99

page 11 - 15
Initial issue, May 01/99

AIRCRAFT ENGINES

MAINTENANCE MANUAL

11.32)

Inspect crankshaft and replace outer seals
The crankshaft is a built-up design with single components
connected by pressfit.
— Check taper (1) on both ends of crankshaft.
— Check external (2) and internal (3) thread.
— Check groove (4) for Woodruff key on magneto-side.
— Inspect outer oil seals. Replace as necessary according to
latest revision of the relevant repair manual 462-532-582.
— Check crankshaft for concentricity on PTO side (5). (Crank
shaft fitted in the crankcase):
maximum out of round: 0,03 mm
— Inspect for corrosion.

fig. 028
5
1
3
02938

4

2

1

General overhaul of the engine
For a general engine overhaul, the engine has to be shipped to an
authorized distributor or Service Center.

Effectivity: 447 UL SCDI, 503 UL DCDI, 582 UL DCDI /mod. 99

page 11 - 16
Initial issue, May 01/99

d00377

11.33)

AIRCRAFT ENGINES

MAINTENANCE MANUAL

12) Required inspections after limits of operation have been exceeded:
12.1) Exceeding of max. permissible engine speed
Remove the cylinders and inspect the pistons for seizure.

12.2) Exceeding of max. permissible cylinder head temperature

d00387

Remove the cylinders and inspect the pistons for seizure and piston crown for
depressions.

Effectivity: 447 UL SCDI, 503 UL DCDI, 582 UL DCDI /mod. 99

page 12 - 1
Initial issue, May 01/99

AIRCRAFT ENGINES

MAINTENANCE MANUAL

12.3) Exceeding of max. permissible exhaust gas temperature
Remove the cylinders and inspect the pistons for seizure.

12.4) Fuel pressure below specified value

d00387

Remove the cylinders and inspect the pistons for seizure. Also inspect crankshaft
end seals for leakage.

Effectivity: 447 UL SCDI, 503 UL DCDI, 582 UL DCDI /mod. 99

page 12 - 2
Initial issue, May 01/99

AIRCRAFT ENGINES

MAINTENANCE MANUAL
Edition 1999 01 05

13)

ROTAX® Authorized Distributors

1) E U R O P E
AUSTRIA:
➤ HB - FLUGTECHNIK GES.M.B.H.
Dr. Adolf Schärf Str. 44
A-4053 HAID
Tel.: 07229 / 79104/79117, Fax: 07229 / 79104 15
Contact person: Ing. Heino Brditschka

BULGARIA:
➤ GERGANOV - AIRCRAFT EINGINES LTD.
25B-Post 20, 23 peh. Shlp. polk Blvd.
BG-6100 KAZANLAK
Tel.: 431 / 27 247, Fax: 431 / 23 777
Contact person: Radosslav D. Gerganov

CROATIA / former YUGOSLAVIA
(except SLOVENIA):
➤SHAFT D.O.O.
B.L. Mandica 161 a
HR-54000 OSIJEK
Tel. + Fax:031 / 280-046
Contact person: Ing. Ivan Vdovjak

CZECHIA:
➤ TEVESO S.R.O.
Skroupova 9441
CS-50002 HRADEC KRALOVE
Tel.: 049 / 56 30 127, Fax: 049 / 56 30 226
E-mail: teveso@mbox.vol.cz
Contact persons: Ing. Samal / Ing. Halek

DENMARK / THE NETHERLANDS:
➤FLIGHT-CENTER
Flugplatz
D-27777 GANDERKESEE, GERMANY
Tel.: 04222 / 3789, Fax: 04222 / 6042
E-mail: flightcenter@olis.de
Contact person: Robert Heilig

FINLAND / NORWAY/ SWEDEN/
ESTONIA/ LATVIA / LITHUANIA
➤ LYCON ENGINEERING AB
Härkeberga, SE-74596 ENKÖPING
Tel.: 171 414039; FAX: 171 414116
E-mail: info@lycon.se
Contact person: Yard Johansson

FRANCE / BELGIUM / MONACO /
LUXEMBURG:

d00378

➤ MOTEUR AERO DISTRIBUTION
11 Blvd Albert 1
98000 MONACO
Tel.:7 93 30 17 40, Fax: 7 93 30 17 60
E-mail: mad.rotax@worldnet.fr
Contact person: Patrick Coyette

GERMANY:
for postcodes 0-5-6-7-8-9:
➤ FRANZ AIRCRAFT ENGINES VERTRIEB GMBH
Am Eckfeld 6e, D-83543 ROTT AM INN
Tel.: 08039 / 90350, Fax: 08039 / 9035-35
E-mail: Franz-Aircraft.EF@t-online.de
Contact person: Eduard Franz
for postcodes 1-2-3-4:
➤ FLIGHT-CENTER
Flugplatz
D-27777 GANDERKESEE
Tel.: 04222 / 3789, Fax: 04222 / 6042
E-mail: flightcenter@olis.de
Contact person: Robert Heilig

GREAT BRITAIN / IRELAND /
ICELAND:
➤ SKYDRIVE LTD.
Burnside, Deppers Bridge
LEAMINGTON Spa. CV 33 OSU
Tel.: 1926 / 612 188, Fax: 1926 / 613 781
E-mail: skydrive@avnet.co.uk
Contact person: Nigel Beale

GREECE / CYPRUS:
➤KINISI
Ellis 1 str. , GR-14563 KIFISSIA
Tel.: 01 / 620 8611; Fax: 01/ 625 0026
Contact person: Michael Poulikakos
Nick Siganos

HUNGARY:
➤ HALLEY
Baktai út 45, P.O. Box 425
H-3300 EGER
Tel.: 36 / 313-830, Fax: 36 / 320-208

ITALY / MALTA:
➤ ICARO MOTORI S.R.L.
Via Emilia, 61/B
I-27050 REDAVALLE (PV)
Tel.: 0385 / 74 591, Fax: 0385 / 74 592
E-mail: icaro@energy.it
Contact person: Corrado Gavazzoni

POLAND:
➤ FASTON LTD.
ul. Szeroka 2
PL-05-860 PLOCHOCIN
Tel.: 22 / 722-5858; Fax: 22 / 840-0196
Contact person: Wojtek Madry, Manager

ROMANIA:
➤ S.C. BERIMPEX S.R.L.
Str. Dr. Taranu Grigore No. 8, Ap. 2, Sector 5
R-76241 BUCHAREST
Tel.: 1-410 90 03; Fax: 1-410 9020
E-mail: c_berar@sunu.rnc.ro
Contact person: Dr. Christian Berar

Effectivity: 447 UL SCDI, 503 UL DCDI, 582 UL DCDI /mod. 99

page 13 - 1
Initial issue, May 01/99

AIRCRAFT ENGINES

MAINTENANCE MANUAL

➤ TEVESO S.R.O.
Skroupova 441
CS-50002 HRADEC KRALOVE
Tel.: 049 / 56 30 127, Fax: 049 / 56 30 226
E-mail: teveso@mbox.vol.cz
Contact persons: Ing. Samal / Ing. Halek

SLOVENIA:
➤ PIPISTREL d.o.o.
Strancarjeva Ul. 11
5270 AJDOVSCINA
Tel. 065 63 873, Fax: 065 61 263
E-mail: pipistrel@eunet.si
Contact person: Ivo Boscarol

SPAIN / PORTUGAL:
➤ AVIASPORT S.A.
Almazara 11
E-28760 TRES CANTOS (MADRID)
Tel.: (91) 803 77 11, Fax: (91) 803 55 22
E-mail: aviaspor@bcsnetwork.es
Contact person: Mariano de Castro

SWITZERLAND / LIECHTENSTEIN:
➤ FRANZ AIRCRAFT ENGINES VERTRIEB GMBH
Am Eckfeld 6e, D-83543 Rott am Inn, GERMANY
Tel.: 08039 / 90350, Fax: 08039 / 9035-35
E-mail: Franz-Aircraft.EF@t-online.de
Contact person: Eduard Franz

TURKEY:
➤ KLASIK HALI A.S.
Klasik Hali is Merkezi, Bozkurt Caddesi No. 25/A
35230 Kapilar / IZMIR TURKEY
Tel.: (232) 441 4911; Fax: (232) 445 1285
Contact person: Tahir Önder, President

2) A M E R I C A
CANADA:
➤ ROTECH RESEARCH CANADA, LTD.
6235 Okanagan Landing Rd.
VERNON, B.C., V1H 1M5, Canada
Tel.: 250 / 260-6299, Fax: 250 / 260-6269
E-mail: inquiries@rotec.com
website: www.rotec.com

NORTH / MIDDLE / SOUTH AMERICA:
➤ KODIAK RESEARCH LTD.
P.O. Box N 7113
Marlborough House Cumberland Street
NASSAU, BAHAMAS
Tel.: 242 / 356 5377, Fax: 242 322 6784
E-mail: custsupport@kodiakbs.com
website: www.kodiakbs.com

3) A U S T R A L I A
➤ AIRCRAFT ENGINE DISTRIBUTORS PTY. LTD.
P.O. Box 84, Boonah, QLD. 4310
Tel.: 07 5463 2755, Fax: 07 5463 2987
E-mail: sales@austflight.com.au
Contact person: Jim Fenton
➤ BERT FLOOD IMPORTS PTY. LTD.
P.O. Box 61, LILYDALE, VICTORIA 3140
Tel.: 03 / 9735 5655, Fax: 03 / 9735 5699
E-mail: flood@smart.net.au
Contact person: Bert Flood

NEW ZEALAND:
➤ TIPPINS INTERNATIONAL
P.O. Box 192, Tuakau
SOUTH AUCKLAND
Tel.: 09 / 233 - 4898, Fax: 09 / 233 - 4798
E-mail: data@ets.co.nz
Contact person: Murray Tippins

4) A F R I C A
EGYPT:
➤ AL MOALLA
P.O. Box 7787, ABU DHABI
Tel.: (2) 723 248, Fax: (2)788 073
E-mail: almoalla@emirates.net.ae
Contact person: Hussain Al Moalla

ANGOLA / BOTSWANA / LESOTHO /
MADAGASCAR / MALAWI /
MOZAMBIQUE / NAMIBIA / SOUTH
AFRICA / SWAZILAND / ZAMBIA / ZIMBABWE:
➤ AVIATION ENGINES ANDACCESSORIES (PTY)
LTD
Private Bag X10021, Edenvale 1610, South Africa
Tel.: 011 / 455 4203/4/5/6/9, Fax: 011 / 455 4499
E-mail: flying@iafrica.com
Contact person: Mike Blyth

5) A S I A
CHINA / HONG KONG / MACAO:
➤ DUEN MU CO.
Flat A, 3/F, Kam Meng Fung
Industrial Building,
6 Hong Man Street, Chai Wan,
HONG KONG
Tel.: 2756 5725, Fax: 2754 4774
E-mail: cali@tfhtech.com
Contact person: W. C. Choi

CIS:
➤ AVIAGAMMA JSCo.
P.O. Box 51, 125 057 MOSCOW
Tel.: 095 / 158 31 23, Fax: 095 / 158 6222
E-mail: vkrag@city.line.ru
Contact person: Vladimir Andriytschuk
General Director

Effectivity: 447 UL SCDI, 503 UL DCDI, 582 UL DCDI /mod. 99

page 13 - 2
Initial issue, May 01/99

d00378

SLOVAKIA:

AIRCRAFT ENGINES

MAINTENANCE MANUAL

INDIA:
➤ GREAVES LIMITED
22-A, Janpath
NEW DELHI - 110 001
Tel.: 11/338 50 61/338 26 53 (Dir.), Fax:11/37 82
553 Tlx.: 031-62663
E-mail:
greaves@GRVSDEL.XEEDEL.XEEMAIL.com
Contact person: Wg Cdr S.N. Chhabra
Divisional Manager

INDONESIA / MALAYSIA / PHILIPPINES
/SINGAPORE / THAILAND / TAIWAN:
➤ TPA PTE LTD.
12 Little Road, #02-01/02
Lian Cheong Industrial Building
Singapore 536986
Tel.: (65) 289 8022
Fax: (65) 289 1011
E-mail:aviation@tpa.com.sg
Contact person: Chan Nyuk Lin

PAPUA NEW GUINEA:
➤ BERT FLOOD IMPORTS PTY. LTD.
P.O. Box 61, LILYDALE, VICTORIA 3140
AUSTRALIA
Tel.: 03 / 9735 5655, Fax: 03 / 9735 5699
E-mail: flood@smart.net.au
Contact person: Bert Flood

UNITED ARAB. EMIRATES:
➤ AL MOALLA
P.O. Box 7787
ABU DHABI
Tel.: 2 / 723 248, Fax: 2 / 788 073
E-mail: almoalla@emirates.net.ae
Contact person: Hussain Al Moalla

IRAN:
➤ H.F. DORNA CO.
P.O. Box 16315-345, Tehran
Tel.: 21 285 4827, Fax: 21 284 1831
Contact persons: Y. Antesary

ISRAEL:
➤CONDOR-AVIATION INDUSTRIES LTD.
P.O. Box 1903, 14 Topaz st.
Cesaria 38900
Tel.:06 / 6265080, 90 / 50-290189
Fax: 06 / 62650 95
E-mail: condor@netvision.net.il
Contact person: David Viernik

JAPAN:
➤ JUA, LTD.
1793 Fukazawa, Gotemba City
SHIZUOKA PREF 412
Tel.: 550 / 83 8860, Fax: 550 / 83 8224
Contact person: Yoshihiko Tajika, President

KOREA:

d00378

➤ HWA YOUNG MEDICAL & SCIENCE CO.
Office address:
401 KeumKang Building
1439-1, Seocho 1 dong, seocho-ku, SEOUL 137-071
Tel.: 02 / 3472-0271-5,
Fax: 02 / 3472-0276 (02/3471-4753)
Contact person: John Lee, President
Mailing address:
SL Kang Nam
P.O. Box 918, SEOUL

Effectivity: 447 UL SCDI, 503 UL DCDI, 582 UL DCDI /mod. 99

page 13 - 3
Initial issue, May 01/99



---

Source Exif Data:

File Type                       : PDF
File Type Extension             : pdf
MIME Type                       : application/pdf
PDF Version                     : 1.3
Linearized                      : Yes
Encryption                      : Standard V1.2 (40-bit)
User Access                     : Print, Fill forms, Extract, Assemble, Print high-res
Create Date                     : 1999:07:07 07:59:53
Producer                        : Acrobat Distiller 3.01 for Windows
Subject                         : MM 447-503-582
Author                          : 
Creator                         : Adobe PageMaker 6.52
Title                           : MM 447-503-582
Modify Date                     : 1999:12:16 07:27:49+01:00
Page Count                      : 60

EXIF Metadata provided by EXIF.tools