Rotax 582 aircraft engine specifications and technical data.

• Intake Silencer Kit with filter (requires jetting modifications)
• After Muffler: Special after muffler fitted to exhaust canister (available in either weld-on type or clamp-on type)
• Air filter: Two K&N RC 1200 or One K&N RC 2820
• Hi gh Altitude Compensator: Automatic High Altitude adjustment of Carburetor calibration with modified Carburetor
• Electric Start Kit: Electric start on MAG end.
• Regulator/ Rectifier: #9103 Single phrase or #9251 three phase
• Reduction Box: "B" box with ratios: 2.0 to 1, 2.238 to 1, or 2.58 to 1
• Reduction Box "C" box with ratios: 2.62 to 1, 3.0 to 1, 3.4 to 1, 4.0 to 1
• Cooling System: Twin Radiator kit #881-432 fitted on engine (not inverted)
  and gear box. 0.62 US gallon capacity.

Rebuilding  the Rotax  582 ultralight aircraft engine.

Wiring

Electronic box (ignition circuit 1)
Electronic box (ignition circuit 2)
eight lighting coils
four charging coils
Pickup (ignition circuit 1)
trigger cable, red
charging cable, green
charging cable, white
Shorting cables, black/yellow
Shorting cables, black/yellow
lighting cables, yellow-yellow/black
tachometer cable grey
mass cable brown
ignition cables
sparkplug connectors
spark plugs
shrink rap tube

*After installing, all the connections have to be protected with shrink wrap tubes.

582 Dual CDI ignition system

Function of the ignition unit:

Two charging coil pairs fitted on the generator stator and independent from each other feed one each ignition circuit. The energy supplied is stored in the ignition capacitor. At the moment of ignition the external triggers supply an impulse to the control circuits and the ignition condensers are discharged via the primary winding of the ignition coil. The secondary winding supplies the high voltage for the ignition spark.

Checking of the ignition unit: To check the ignition the engine must be operated at 3000 to 3500 rpm. Switch one ignition system off. The RPM should not drop more than 300 RPM. Turn the ignition system back on. Switch the other system off. Again the engine should not drop any more the 300 RPM.

Attention: When flying both ignition systems must be switched ON

With the engine running the trigger cable (RED) MUST NOT be disconnected from the electronic box. This could destroy the box.

Lighting circuit

In the stator 8 lighting coils are incorporated. The output is 170 W. A.C. and 13.5 Volts effective at 6000 RPM. This alternating current can be used directly to feed A.C. consumers, or via a rectifier-regulator for loading a battery and feeding direct current consumers.

To operate loads requiring direct current (e.g. battery), a rectifier regulator is required. A rectifier-regulator, part no 866 080, is available. For feeding lights only, (14) this rectifier-regulator can also be used without battery. In this case the regulated RMS voltage will be between 11 and 12 volts as long as a minimum load of 1 amp is provided.

If a battery is used it has to be capable of absorbing approximately 1 amp. minimum continuous charging load even with full battery (suggested minimum battery capacity: 9 am;. hour resp. 16 amp. hour with electric starter. Regulated voltage is 13.5 to 14.5 volts.

Caution: To avoid the voltage to rise above permissible levels use a voltage regulator.

Rotax electric start installation

A Rotax Electric Mag End Starter Kit using a ring gear and Bendix drive system is available to fit the 582 Rotax liquid cooled, ultralight aircraft engines.

A spacer and 6 inch steel ring gear assembly are mounted onto the magneto with three bolts, which add 24 ounces to the rotating mass of the engine

To install the starter, it is necessary to remove the starter assembly and recoil starter pulley. Then determine the position the starter is to sit in. Positions available on the 582 are at the 6 / 12 o'clock positions.

Using the template supplied with the starter cut a hole in the starter housing at either the 6 o'clock or 12 o'clock position. To do this drill a series of small holes in the housing, using the template exterior as a guide. Then come in with a hacksaw, making sure to prevent any filings from entering the magneto, join the holes together, once the casings has been cut out use a file to round off any rough edges. Again be very careful while notching the housing, do not allow filings to enter the magneto.

Warning Warning Warning.

On dual CDI equipped engines be extremely careful that damage is not done to CDI units mounted in crankcase casing.

Charging system:

A regulator rectifier (not supplied with starter kit) is needed to convert the AC voltage to DC voltage in order to recharge the battery. Rectifier 866 080 is recommended. This rectifier requires a minimum 1 amp draw from the battery source.

A battery of 20 amps is required for the electric start and should be a maintenance free re-chargeable type. These are especially designed for long life, rugged durability, and dependable service. It has a unique suspended electrolyte and venting system which allows the freedom to mount this battery in any position without fear of leakage or loss.

Wiring

Ground and power cables should be a minimum of 6 gauge
Terminals should also be 6 gauge
There should be an in line fuse of 15 amps in the system
The ignition switch should be an on off, dual pole, single throw, with screw terminals.
Solenoid must be isolated from heat and vibration

Main torquing specifications

NM in.lbs.
Note the first number is in Newton meters (NM) the second is in inch pounds (in. lbs.)
e.g. - Crankcase screws M8 - 24 NM or 210 in. lbs.

1.Crankcase screws M8 - 24 - 210
2. Crankcase screws M6 - 10 - 90
3. Crankcase nuts/screws M10 - 38 -335
4. Crankcase studs M10 -12 -105
5. Cylinder studs M8 - 7 - 60
6. Cylinder head studs M8 - 7 - 60
7. Cylinder head nuts M8 - 22 - 195
8. Magneto housing nut M22x1.5 - 90 - 800
9. Allen screws starter pulley M8 - 22 - 195
10Hex. screw for starter M6 - 10 - 90
11.Rotary valve cover screws M8 - 22 - 195
12.Intake rubber flange screws M8 - 14 - 125
13.Lock nut for oil pump gear M6- 5 - 45
14.Banjo bolt for oil pump M6 - 6 - 55
15.Cyl. screw for oil pump M5 - 5 - 45
16.Spark plug (cold engine) 14 - 27 - 240
17.Allen screw for stator plate M5 - 6 - 55
18.Tapetite screw for pickup M5 -6 - 55
19.Hex. screws for ignition coil M6 - 10 - 90
20.Hex. screws for mounting plate M6 - 5 - 45
21.Hex screws for starter gearM8 - 22 - 195
22.Studs for outlet socket M6 - 3 - 25
23.Hex nut for outlet socket M6 - 10 - 90
24.Lock nut water pump impeller M6 - 6 - 25
25.Tapetite screw water pump housing M6 - 8 - 70
26 .Studs for gear box M8 - 8 - 22
27.Hex nut for gear box M8 - 22 - 195
28.Hex screw for drive gear 1/2-20Unf - 60 - 530

TECHNICAL DATA
Spark plugs:  NGK B8ES or equivalent
Spark plug gap:.015 to .019 thou