Removal -Engine from aircraft
To remove the 582 Rotax liquid cooled engine from the aircraft it may be
necessary to remove or disconnect the following if necessary
- drain then disconnect cooling system from engine
- disconnect fuel lines
- disconnect fuel pump
- disconnect throttle cables
- disconnect air filter or air intake silencer box
- disconnect carburetors at rubber intake flange
- disconnect wiring harness from engine
- disconnect any temperature sending units from engine
- remove prop and store in safe place
- if necessary disconnect reduction drive
- if necessary remove recoil
- if convenient remove exhaust system
- remove remaining engine assembly from aircraft
Caution Engine is extremely
heavy and awkward.
Do not attempt to remove from aircraft without adequate help
Caution If aircraft is
equipped with a battery disconnect the battery
ground cable before starting any work
Caution If engine is hot
allow to cool before starting any work
Attention
Prior to disconnection label all wiring for proper reinstallation
Disassembly -Exhaust Manifold/Recoil removal
Tools Required:
10 mm deep reach socket |
6mm allen wrench |
ratchet |
Procedure
With a 6 mm allen wrench loosen, then remove the 4 allen head screws used to retain the
exhaust manifold to the cylinders. The manifold will then come free.
Using the 10mm deep reach socket and ratchet remove the 4 bolts, or 6mm allen head screws
retaining the recoil to the two crankcase halves
Once the 4 bolts/screws have been removed the recoil will come free.
Inspection:
Inspect ball joint at end of exhaust manifold for wear.
Inspect manifold, for warpage.
Inspect the recoil housing for cracking around the center, and where the recoil rope exits
the housing.
Inspect for proper recoil return spring action.
Inspect the recoil rope for fraying.
Attention Note the position of the recoil in relation to the
engine installation for proper recoil starter rope angle during reassembly.
Disassembly Starter pulley assembly
Tools Required |
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6 mm allen wrench |
13 mm socket |
ratchet |
locking pin |
plastic mallet |
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Procedure.
Located behind the recoil starter assembly is the starter pulley .To remove it lock the
crankshaft, by placing the locking pin (supplied with the Rotax engine tool kit), into the
fuel pump impulse hole.
Then slowly turn the engine over until it locks.
With the crankshaft locked use a 6mm allen wrench, electric start models use 13 mm socket
head bolts, to remove the 3, retaining bolts. This allows the removal of the recoil cup.
Caution This is a special locking
pin developed for this purpose. The use of any other tool, or material may cause serious
damage to the engine.
Rebuilding the Rotax 582 ultralight aircraft
engine.
Tools Required |
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Locking pin |
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Ratchet |
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Magneto puller |
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30mm socket |
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Part # 940-580 |
3 bolts, proper length |
Procedure
To remove the magneto nut from the end of the crankshaft, install the
outer half of the flywheel puller. To align the holes in the puller correctly, rotate the
crankshaft. Position the puller so that the puller extension locks into the hole in the
lower crankcase half. With the puller bolts snug and the crankshaft locked use a 30 mm
socket and ratchet to remove the magneto nut, and lock washer. In order to allow the
socket to fit inside the puller half it may be necessary to grind the sides of the socket
down.
Caution Make sure
that the puller bolts are the correct length. The use of incorrect bolts can strip the
magneto threads and/or damage the internal coils.
Disassembly Magneto removal
Once the nut and washer are removed install the inner half of the puller.
With the puller locked in position and the 3 bolts snug, turn the puller bolt in using a
wrench, or socket. If a considerable amount of pressure is required remove the socket and
using a hammer,. carefully, strike the puller bolt sharply. Re-install the socket and
tighten down on the puller bolt, until the magneto comes free. Then by hand pull the
magneto clear of the crankshaft and engine.
Inspection:
Inspect the key way area for signs of wear.
Inspect the interior of the magneto for foreign material.
Inspect the crankshaft end for signs of wear.
Inspect lock washer and nut for signs of damage.
Caution During
removal of the magneto, the key used to align the magneto to the crankshaft may come
loose, and can be easily lost. When pulling the magneto free be careful not to loose the
key, or that it does not get pulled into the magneto.
Disassembly - Carburetor removal
Tools Required
Small Phillips screw driver
Blade screw driver
Procedure
If still connected use a blade screw driver and remove air cleaner(s) from
carburetors. Then using a Phillips screw driver loosen clamp retaining carburetors to
rubber intake manifolds. With the clamp loose gently pry down and back on carburetor and
it will come free of manifold..
Inspection
Inspect rubber intake flanges for damage or cracking.
Inspect carburetor bowl gasket for pinching or cracking.
Inspect floats for leakage.
Inspect air filter (s) for damage .
Update
Replace rubber sockets if cracks are present.
Disassembly -Draining rotary valve oil
Tools Required
ratchet
13 mm deep reach socket
blade screw driver
Shop supplies
Oil drain pan.
Procedure
Before removing the rotary valve tank bracket, it is first necessary to
drain the rotary valve tank. On early model engines it will be necessary to remove the
hose connected to the tank, from the outlet located directly below the carburetors, on an
engine installation where the spark plugs are facing up.
To do this. loosen off the tank cap, use a blade screw driver, and loosen the lower hose
clamp, then using the screw driver, while exerting pressure on the hose gently remove the
hose from the outlet. This will allow the oil to drain from the engine and rotary valve
tank.
On new model engines there will be a drain plug (10mm socket head) located directly below
the water pump housing on the exhaust side of the engine. Removal of the drain plug will
allow the oil to drain from both the tank and engine.
Caution Once the rotary
valve tank hose, or the drain plug, is removed the oil will spill out.
Disconnect lower hose here
(Early models) Remove drain plug here
(Later models) Loosen cap before draining system
Disassembly - Rotary valve tank bracket
Tools Required
10 mm deep reach thin walled socket
13 mm deep reach socket
ratchet
blade screw driver
Procedure
Using a 13 mm deep reach socket remove the two top bolts retaining the
rotary valve cover plate to the engine. Loosen but do not remove the two lower bolts. Using
a 10 mm deep reach thin walled socket remove the two 10 mm nuts, flat washers and lock
washers holding the water outlet socket in place. It may be necessary to push gently over
on the rotary valve hose to allow placement of the socket. With these removed gently tilt
the rotary valve plate outward, then using a blade screw driver loosen off the clamp
holding the rotary valve hose to the top engine outlet. With the hose removed the complete
bracket with coils will now come clear of the engine.
To remove the bracket completely, disconnect the two wires running to the
ignition
suppressor box, and the two leads running to the top of the coils. Next remove the nut
from the back of the bracket which retains the bolt holding the ground wire. With all the
wiring removed the plate should be come free of the engine.
Warning
There is little room between the end of the bolts and the cylinders. Incorrect bolt
installation on reassembly, can cause severe damage to the rotary valve plate securing
ears.
Remove top two bolts, but only loosen bottom two bolts.
Disassembly - Rotary valve plate and rotary valve
Tools Required
Ratchet
13 mm socket
Procedure
To completely remove the rotary valve plate remove the two remaining bolts
from the bottom of the plate. Carefully lift the cover off. Remove the rotary valve, wrap
it in cloth, and store in a safe place. Be careful not to loose or damage large sealing 0
ring.
Inspection:
Inspect hoses for damage
Inspect tank for damage
Inspect tank bracket for damage
Inspect tank cap for wear or damage
Inspect rotary valve plate for damage
Inspect intake manifold flanges for wear/damage
Inspect washers for damage
Inspect ignition coils for damage/wear at retaining brackets
Caution
Wrap rotary valve in
cloth and store in safe place.
Rebuilding the Rotax 582 ultralight aircraft
engine.
Disassembly - Cylinder head
Tools Required.
13 mm socket
ratchet
Procedure.
To remove the cylinder head remove the, 13 mm nuts located in the top of the cylinder head
starting from the outside of the head and working in. Lift the cylinder head off. Remove
the head gaskets. Remove two outer rubber sealing rings
Inspection:
-Inspect the interior dome of the cylinder heads for signs of damage.
-Inspect the cylinder head rings for signs of leakage or damage
-Inspect outer sealing rings for damage
Disassembly - Cylinder Removal.
.Tools Required
..Rubber mallet
Procedure
To remove the cylinders use a 13 mm thin walled deep reach socket, or 6 mm allen wrench
depending on which your engine has and remove the 4 bolts/screws holding the cylinders to
the upper crankcase.
With the nuts/screws removed the cylinders can be GENTLY lifted off. Be EXTREMELY careful
that damage is not done to the piston skirts during removal of the second cylinder.
Inspection:
-Inspect the interior of the cylinder for signs of wear or damage.
-Inspect the interior of the cylinder for signs of seizure.
-Inspect the interior of the cylinder for signs of aluminum deposits.
-Inspect the cylinder with your finger about 5/8 of an inch from the top for signs of
wear.
Caution:
During cylinder removal ensure that the pistons and connecting rods do not bang against
the side of the crankcase halves.
Disassembly - Removal Wrist pin clips
Tools Required
Cir clip removal tool- #H4435
Rag or paper towel
Eye protection
.Procedure.
For disassembly it is only necessary to remove two wrist pin clips, the clips on the PTO
side and Magneto side of the pistons.
While wearing eye protection, carefully insert the point of the tool into the groove on
the side of the wrist pin hole, until it is under the wrist pin clip.
Using a rag or a towel with your other hand cover the clip area. Now slowly apply pressure
and pry the clip out.
Caution:
The wrist pin clip is very springy, use a rag or other material to prevent it from flying
free. Wear eye protection. Clear work area of bystanders.
Disassembly -Removal Wrist pins
Tools Required
-wrist pin puller/socket/screw driver
-small hammer
Procedure
To remove the wrist pin raise the magneto piston to the top of its travel. Insert the
wrist pin puller Part # H 4430 through the pin, lock the puller clip tighten up the puller
and extract the pin.
To remove the wrist pin with a socket, use a socket that is a smaller diameter than the
pin (a 10mm deep reach thin walled socket with a short extension works). Come in from the
side of the pin that still has the wrist pin clip in it, gently apply pressure until the
pin comes free.
Inspection:
-Inspect the wrist pin clip retaining groove for signs of wear.
-Inspect the wrist pin bearing for signs of wear or contamination.
-Inspect the wrist pin for signs of bluing ( an indication of heat), wear, or damage.
Inspect for slop in piston the up and down direction
Warning:
If your engine is equipped with cageless wrist pin bearings these bearings will fall out
once the wrist pin is removed. Take whatever steps necessary to prevent their loss. There
are 31 needle bearings in the new cageless bearings.
Disassembly -Removal Pistons
Procedure
Once the pin is free remove the piston, and wrist pin bearing. To prevent damage to the
piston never place the piston on its skirt, always lay it on its dome. Using marker or
scribe to identify pistons magneto and PTO.
Repeat the procedure for the piston on the PTO side.
Inspection:
-Inspect the dome of the piston for signs of damage.
-Inspect the dome for signs of carbon build up, and ignition burning pattern.
-Inspect the rings for signs of damage.
-Inspect the piston sides for signs of seizure.
-Inspect the rings for signs of seizure and carbon build up.
-Inspect the ring dowels for signs of damage or wear.
-Inspect the ring lands for signs of damage/wear/carbon build up.
-Inspect the piston sides for signs of wear or damage.
-Inspect the base of the skirts for shine, indicating piston slop.
-Inspect the underside of the piston dome for carbon build up.
Warning:
If your engine is equipped with cageless wrist pin bearings these bearings will fall out
once the wrist pin is removed. Take whatever steps necessary to prevent their loss. Ensure
you have 31 bearings.
Disassembly - Stator unit removal
Tools required
4 mm allen wrench
Procedure
Remove the 4 screws retain the 2 ignition pickup units. Note correct routing of wiring
Before removing 2 pickups.
Remove the two allen screws, washers, and lock washers holding the stator plate to the
crankcase halves. Remove rubber grommet protecting wires. The stator unit will now come
free, slowly pull the stator plate out while carefully pulling the wiring harness through
the crankcase hole. Once the wires are free the stator unit can be completely removed from
the engine.
Inspection:
-Inspect the stator unit for signs of wear or damage.
-Inspect the coils for damage.
-Inspect the wiring for wear, cuts, or pinching.
Disassembly -Stator unit removal
Tools Required
..4 mm allen wrench
hammer
Procedure
.. Note routing of wiring
Remove the two allen screws, washers, and lock washers holding the stator plate to the
crankcase halves. Remove rubber grommet protecting wires. The stator unit will now come
free, slowly pull the stator plate out while carefully pulling the wiring harness through
the crankcase hole. Once the wires are free the stator unit can be completely removed from
the engine.
.Inspection:
..-Inspect the stator unit for signs of wear or damage.
-Inspect the points and condensers for signs of oil contamination.
-Inspect points for signs of wear.
-Inspect the coils for damage.
-Inspect the wiring for wear, cuts, or pinching. .
Caution:
Be careful not to cut or bare the wires on the sharp edges of the crankcases while pulling
them through the crankcase hole.
Rebuilding the Rotax 582 ultralight aircraft
engine.
Disassembly - Separating crankcase
Tools Required.
Ratchet
10 mm socket
13 mm socket
6 mm allen wrench
Screw driver
Rubber mallet
Procedure
To separate the crankcase halves, turn the remaining engine
assembly upside down. Remove the , 10 mm socket head bolts from
the outside of the cases. Remove the remaining 13 mm/6mm allen
socket head bolts, from the casing, starting from one end and
working to the other.
With all of the bolts removed, insert a screw driver into
the non sealing area between the crankcase halves and pry up
gently in several places on both sides of the casing.
Note:
Some of these 13 mm bolts at the PTO end of the casing have
been changed to allen head screws to allow for easier socket, and
gear drive installation.
Disassembly - Crankcase
Then using a rubber mallet gently tap the crankshaft at
either end to break it free from the casings. The bottom crankcase
should now come free.
After the bottom case has been removed, remove the
crankshaft, by placing your hands around the crank at either end
and using your thumbs pry down on the casing while lifting up on
the crank until it comes free.
Inspection:
.-Inspect the bolts for signs of corrosion.
-Inspect the seals for signs of leakage.
-Inspect the crankcase halves for signs of damage.
-Inspect the crankcase halves for signs of wear in the
bearing retaining areas.
-Inspect the crankshaft bearings for signs of wear.
-Inspect the connecting rods for signs of wear or heat.
-Inspect the center crank spacer for signs of seizure.
-Inspect the crankshaft key way for signs of wear.
-Inspect rotary valve sealing area
-Inspect rotary valve shaft
-Inspect rotary valve gear.
Disassembly-Rotary valve shaft
Tools Required
10 mm socket
ratchet
screw driver
Snap wring pliers
Hammer
Procedure
Using the snap ring pliers remove snap ring from carburetor
end of rotary valve shaft.
Water pump housing/impeller removal
Remove the water pump housing, it is retained by 4, 10 mm
socket head self threading bolts. This will expose the water pump
impeller and retaining nut. Remove the 10 mm nut, and flat washer.
Remove the impeller, remove the special serrated washer and flat
washer.
Located directly below the exhaust manifold is the water
pump housing, it is retained by 4, 10 mm socket head self
threading bolts, remove these and the housing can be removed.
This will expose the water pump impeller and retaining nut.
Remove the 10 mm nut, and flat washer. Remove the impeller, remove
the special serrated washer and flat washer.
Caution:
It may be necessary to gently tap the housing with a plastic
hammer to break it free from the sealing gasket.
Caution:
It is sometimes necessary to apply pressure to the sides of
the water pump impeller to break it free from the shaft.
Disassembly-Rotary valve shaft .
Procedure
Insert the extrusion jig (part # 876 612) onto the water
pump end of the rotary valve shaft, threading it in until it is
butts against the end of the shaft.
Carefully, and forcefully strike the end of the jig with a
hammer. This will drive the rotary valve shaft out the intake side
of the crankcases.
Tools Required
Hands/finger
small screw driver
extrusion jig
hammer/press
half of bearing puller tool
.Procedure
Pressing the gear end of the rotary valve shaft against your
body, with your fingers apply pressure down on the spring holding
cup, (2) break the circlip (1) free from its retaining groove on
the rotary valve shaft. This will allow removal of the spring (3)
gear (4) shim O ring (5).
To remove bearing, spacer and shim, install the lower half
of a bearing puller in behind the bearing, supporting the bearing
and shaft carefully hit the end of the extrusion jig protecting
the other end of the shaft.
Disassembly-Rotary valve shaft
Another procedure that can be used is a small press. Support
the bearing., and shaft then gently press down on the jig
protected end of the shaft until the bearing, spacer and shim come
free.
Bearing removal
To remove remaining bearing insert bearing removal tool, 876
500 into exhaust side of rotary valve hole and carefully and
forcefully strike with a hammer until bearing comes out.
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