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RotacRepair.ca
Приєднався 24 бер 2015
Rotax aircraft engine repair, maintenance, service
Rotax 582UL, spark plug won’t thread
Repairing of damaged cylinder head spark plug thread. Repair can be performed on completely assembled engine, no need to remove the cylinder head.
Переглядів: 585
Відео
Is YOUR aircraft fuel tank melting ?
Переглядів 606Місяць тому
E10 gasoline degradation of a fibreglass fuel tank.
Rotax 503 / 582 Crankcase sealing surface cleaning
Переглядів 367Місяць тому
This is the damage free cleaning method I use. It’s extremely important to preserve the sealing surface integrity of the crankcase.
Rotax 503 / 582 Crankcase Sealer
Переглядів 5762 місяці тому
The application of Rotax 503UL crankcase sealer plus assembly tips.
Rotax 503 with a clutch
Переглядів 5253 місяці тому
The removal of an aftermarket gearbox clutch during Rotax 503UL engine maintenance. Follow along as I describe the clutch operation and successfully remove it without damage.
Rotax 503 DCDI Ignition Timing Adjustments
Переглядів 8943 місяці тому
Adjusting the DCDI timing and air gap on a Rotax 503UL engine
Rotax Mikuni pulse fuel pump screwdriver
Переглядів 9034 місяці тому
A J.I.S. screwdriver is required even if it looks like a Philips screw head.
Ethanol gasoline testing for your Rotax
Переглядів 1,2 тис.4 місяці тому
Simple fuel test to determine if Ethanol is present or not
Rotax Exhaust Gas Temperature probe K type repair and calibration
Переглядів 6974 місяці тому
How I successfully repaired and tested the calibration of K type E.G.T. probes. A description of how the E.G.T. probe powers the gauge to indicate the temperature correctly.
Rotax manifold with stripped E.G.T. probe thread
Переглядів 3735 місяців тому
Removing a totally seized EGT fitting and the replacement of the threads in the exhaust manifold.
Rotax 185 engine run-up
Переглядів 3836 місяців тому
Start up of engine #2 including a detailed description of the compression release system.
Rotax 185 ignition installation and adjustments
Переглядів 4146 місяців тому
I’ll be adjusting the ignition point gap, setting the E-gap and adjusting the ignition spark timing using a dial indicator and a buzz box
I’m back at the shop
Переглядів 2366 місяців тому
Been off work since before Christmas and missed New Year celebrations too. Back at the shop now.
Rotax 185 engine block assembly
Переглядів 3657 місяців тому
Complete engine block assembly process. Determining the crankshaft end clearance, heating and fitting the crankcase, refacing the cylinder head surface and cylinder top surface and preparation of the copper head gasket with sealer.
Rotax 185 copper head gasket fabrication
Переглядів 1 тис.8 місяців тому
An obsolete head gasket is duplicated using copper. Follow along on the process of hoe I make two new copper head gaskets.
Rotax 503UL is there a crankshaft seal separating both cylinders?
Переглядів 7539 місяців тому
Rotax 503UL is there a crankshaft seal separating both cylinders?
Rotax 503UL engine pressure testing
Переглядів 1,4 тис.9 місяців тому
Rotax 503UL engine pressure testing
Rotax 582 Mikuni fuel pump bench testing and repair
Переглядів 6 тис.10 місяців тому
Rotax 582 Mikuni fuel pump bench testing and repair
Rotax 618 R.A.V.E. valve installation
Переглядів 47710 місяців тому
Rotax 618 R.A.V.E. valve installation
Rotax 912iS fuel pump assembly repair
Переглядів 57310 місяців тому
Rotax 912iS fuel pump assembly repair
Rotax Troubleshooting seminar held at the U.P.A.C. 2023 convention
Переглядів 92211 місяців тому
Rotax Troubleshooting seminar held at the U.P.A.C. 2023 convention
Rotax 618 R.A.V.E. valve dismantle and cleaning
Переглядів 61911 місяців тому
Rotax 618 R.A.V.E. valve dismantle and cleaning
Rotax 447 (part 4) measuring piston to cylinder clearance and determining the base gasket thickness
Переглядів 800Рік тому
Rotax 447 (part 4) measuring piston to cylinder clearance and determining the base gasket thickness
Rotax 447 (part 2) specialized crankshaft inspection
Переглядів 652Рік тому
Rotax 447 (part 2) specialized crankshaft inspection
Rotax 447 single carb single CDI dismantling (part 1)
Переглядів 2,1 тис.Рік тому
Rotax 447 single carb single CDI dismantling (part 1)
Rotax 582 Blue head (part5) removing stuck propeller mounting bolts
Переглядів 725Рік тому
Rotax 582 Blue head (part5) removing stuck propeller mounting bolts
Rotax 582 Blue head (part4) Testing the thermostat
Переглядів 1 тис.Рік тому
Rotax 582 Blue head (part4) Testing the thermostat
Rotax 582 Blue head (part3) resurfacing the cylinder head
Переглядів 1,2 тис.Рік тому
Rotax 582 Blue head (part3) resurfacing the cylinder head
I’ve noticed oil drops fro my 503 carburetor filter after I fly ,what could that means ?
I’ve noticed oil drips from the carburetor oil filter after the flight,what could that be ?
Hi, is your 503 operating on premix or oil pump?
Knowledge is power; thank you very much.
You are very welcome
My guess would have been that they were off a Lazair, they are a little bit big for a CriCri!
You are correct, Lazair
Plz ans me
I like u fule gaga sence
Fule gaga sence 375mm ok how much Pakistan money price
Great vid. Thank you for taking time to make this.
Glad you enjoyed it!
Thanks for the information John
You’re very welcome!
Thanks John. That's a nice little tool and your explanation was perfect. You just got a new subscriber from Brazil. 👍
Thanks for the sub!
The only caveat I would provide is that to do the repair you are actually removing material. Depending on how badly the cylinder head has been cross threaded, isn’t it possible that the repair could result in the plug not being able to be torqued properly? I had a repair done on my 503 by a technician for the same reason and even though I could torque the plug it came out in flight. I ended up replacing the cylinder head.
It actually removes very very little material, it’s more of a realignment of the threads. Torques up perfectly. No issues at all. I do know that if any type of thread replacement sleeve is installed it absolutely will fail and the spark plug will fly out.
Really interesting tool there, John - never seen one of those before. Thanks for sharing. 🙂👍
You’re welcome, it really is a cool tool!
The real problem is when you get resistance putting a spark plug in, and just grab a wrench and force it in all the way. Someone who does that, deserves the cost of repairs. Great video as always. Cheers from Winnipeg.
Thanks, it was enjoyable to show a way to repair rather than replace a component.
YES that is a really cool tool. THANKS.
@@donsipes absolutely, saved that head now the threads are perfect again. Hope the owner adopts the by hand method of installation.
Never seen one of these tools. Volkswagen beatles used to give me spark plug thread problems. I always used a thread chaser in all cylinder holes needed or not before installing new plug just to be safe. This actually straightens the damaged metal. Very cool. Just learned something useful here - not just for rotax either. Cheers. 👍
I remember those cars, I also wish I knew about this tool back then! Mmm I wonder if it had invented yet? I’ll need to check the package for a patent date.
Great to know, Thx John
You bet!
Useful information as always! Neat technique!
Glad it was helpful!
Thanks John for your time in trying to educate us , Great video
Your welcome, the more the information is shared the better.
Thx John, this is another eye opener.
Sure is!
Good job
Thank you, happy flying!
Have you done any videos on repairing and/or replacing the banjo check valves on the oil injected Rotax engines?
Not yet, it’s on the list for a video
The old oil looks pretty clean, making me wonder if changing the oil is necessary.
Replacement of the rotary valve oil at 100 hours is recommended. Even clean looking oil will contain extremely small wear particles from the brass gear.
How is this not an airworthiness directive for inspection??
I believe that would be prudent.
Thanks for the warning. Ethanol does dissolve many plastics but that is not the only problem with fuel that contains ethanol. Ethanol will absorb water from the air and form an ethanol-water solution. If that is exposed to the air it will absorb acetobacter which will convert the ethanol into ethanoic acid. That acid will then react with most common metals like aluminum to form salts. This causes pitting and will leave small crystals where the metal used to be. One way to prevent problems is to drain the fuel completely after every use. The other alternative is to remove the ethanol. If the fuel is agitated with water the ethanol will move into the water. IF the water is then decanted the remaining fuel will be ethanol-free. There is no simple solution to this problem as long as goverments continue to mandate ethanol in the fuel.
Thank you for the superb input. Yes it absolutely absorbs water. I’m always stating “after 30 days in the tank, drain and refill with fresh fuel”
@@RotacRepair You are welcome and I think your video is important for engine reliability. It would make sense to ban ethanol-blend fuels for aviation. It is not like an aviator can pull off to the side of a cloud, set the parking brake, and wait for a tow truck to come and tow the aircraft into the shop. It would make more sense to give people the option to buy ethanol-free fuel if that is what they want to use.
John! I love your insight and videos! How much for a tank?!!!! $$$
Please email me, rotacrepair@gmail.com
Great video John. I have the same tank. Looked good when I got the plane in 2022. Only ran Esso 94 or 91, which then was still ethanol free. By 2023 the ability to find the ethanol free gas was getting harder, and by the end of 2023, I do not think anyone was advertising ethanol free in Ontario, but some may differ. Our local station uses Esso 91, I tested it, and it definately has ethanol. My filler tube had an issue last fall, collapsed on itself. After several attempts to fix I finally Sealed (sealall) it to the filler hose, (which originally was just radiator hose) which was gas rated. Have not had a problem with that since. As for the tank, I do not remember discolouration when I got the bird, but now it has a mottled appearance. I will see if I can find some pics from 2022. I have not noticed a problem with discolouration in the gas, or the filter, but I pulled most of the gas out when it did not fly for a few months. As for carbon buildup, when I pulled the engine for its 150 hour, the piston tops were black, the lower rings locked in solid with carbon, and the upper rings half locked. I wrote that off to 1/ its first 40 hours it ran rich due to the carb needles put on top of the white plastic slide (before I bought it). 2/ my last 1.5 hours running were tethered trying to sort a charging issue with most of that time running at 3k rpm. Perhaps the resin in the fuel was a contributor. We tore the engine down to the crank, and notice no other issues as you described, nothing of note on the piston sides below the rings, and no resin building on the crank or anywhere else. I had ordered a tank in the fall when I had the issue with the neck, but it never did get shipped, and I didnt push it as the replacement likely meant moving the fill point and other hassles. Flying "on condition" keeping an eye on it. Also considering switching to wing tanks. Great video again.
Please proceed with caution, I believe from your description you have all the melting tank symptoms.
What is your opinion on using 100LL in a 503 or 582?
100LL is far more octane than a 503-582 requires, however when I’m on a trip I have occasionally used 100LL. Its very expensive compared to car gas, it kills the spark plugs in 25 hours and dirties up the inside of the engine. On the plus side your fuel tank won’t melt.
So what's the solution here? Do we all buy aluminum tanks from John? What are the thoughts on alcohol resistant gas tank sealers like POR15? Coat the inside of fiberglass tanks with this??
@@VerticalSpeed1987 I know of one tank sealer material that won’t stick properly if the tank has ever used premixed.
Looks like the epoxy is failing, resulting in delamination.
Correct, that is the warning I’m attempting to pass along. Thanks for your comment.
Correct, that’s the warning I’m attempting to pass along. Thanks for your comment.
More signs that the governments all around the world are out to kill us with the senseless climate crap.
Good info 👍
Thanks 👍
What about the plastic 10 gallon tanks? Are they affected by the ethanol?
The “plastic” fuel tank are not affected by ethanol, it’s just the fiberglass tanks.
I fly a 503 and I currently buy ethynyl-free fuel. E10 85 octane is OK to burn in my Rotax engine?
87 A.K.I. rated gasoline is minimum for a 503.
use vinyl ester resin.
Thanks for your suggestion, however it’s aluminum for me.
Ceramic scraper or plastic utility cover plate works as well 11:49
Two good suggestions, Thanks for the tip
Once all that cleaning and such is done. What 2 stroke oil would be best for engine protection, where the engine has oil injection. I keep getting all sorts of advice from people who I'm sure mean well, but coming from someone who rebuilds engines and knows what does the least damage is my preferred source of information. I do have a feeling that this may be a bit of a controversial topic, kind of like which beer is best for a summer time BBQ. Cheers from Winnipeg.
Controversial is correct! I personally use Castrol Super Snowmobile 2T. I find it has great corrosion resistance, mixes easily with neat gasoline, E10 and 100LL, it’s readily available in my area and is reasonably priced. The 1 litre container part number is 0017442, the 4 litre container part number is 0017431. Everyone is welcome to use their favourite flavour of oil, however when I’m directly asked, this is my recommendation.
Thanks John. Good episode. A couple of questions: What's your take on vapor blasting? I'm not sure what the medium is but I hear good thinks about it! What do you do when the guy before you has not been as diligent and surfaces are scratched up? CHEERS!
I’m not very knowledgeable about Vapor blasting. I’ve seen what I would consider good and poor results, I’m sure it is dependent on the secret recipe of blasting media. It’s interesting to note that the walnut shell will easily remove carbon from the piston dome and ring groves, however it’s gentle enough to not remove the magic marker where I’ve written on the piston skirt. Quite amazing!
If the crankcase sealing surface has been damaged by abrasive cleaning it’s pretty much scrap. While the low areas may initially seal at assembly, there’s a good chance that the unsupported sealer areas could blow out. Then the resulting lean mixture could be fail the engine. The crankshaft bearing crush may also be affected. I wouldn’t risk it, cheaper in the long run not to use a crankcase with damaged sealing surfaces.
Thank you so much! For some reason, despite having a 20# box of crushed walnut shells sitting Bach in the shop for 6-7 years, I’ve never used them nor I have thought to use them to lean case halves. Betcha I do next time. We so appreciate your videos and the information you share. Thank you so Much!,
Your welcome. Mmmm, I would imagine the next 20# bag will be more expensive than that one. Happy flying!
Thank you for sharing all the information you do. Very informative and helpful. I have great success using starting fluid and a paper towel to get most sealants off aluminum components. It's a little slower but it does work if u don't have a walnut blaster. It just simply melts the sealant and it usually just sorta rolls off. Then go back with brake cleaner to prep for final assembly. Now I will say that all starting fluid is not the same. The key is the ones with the highest either content. Over the past few decades the either content has been lowered across the board for safety and environmental concerns I'm sure. Diesel fuel or kerosene ( which is almost identical) works great also but just messy to deal with. Now I'm not suggesting anyone try any of this. But it does work and we've been doing it for ever around here. Another option for someone is to just take the part to their local engine shop and have them clean it. The main goal, as you pointed out, is to get the part absolutely clean and oil free with no scratches. Anyway, thanks again for sharing your expertise.
There’s always more than one way to get there. I hadn’t thought about using starting fluid or diesel. I. Your method certainly has been successful for you and won’t scratch or harness the surface. Thanks for the tip.
Thanks, John - another very interesting watch. 🙂
Your welcome! And unlike other crankcase sealer videos out here, I’ve still got sealer reminding in the tube for next time. Lol
I love your videos John! Thanks for doing them!!
Glad you like them!
It is possible to change the seal withaout open the motor???
I would certainly advise against changing an engine seal by that method. If the engine has a seal leaking it’s likely long past the recommended inspection interval.
Dear Mr. Baker: I have been a mechanics enthusiast since I was old enough to hold a screwdriver in my hand. I am old school, I have learned from the experience and advice that great engine professionals have given me over the years in their workshops. Then UA-cam arrived and my mechanic friends could take a break from a nosy parker customer. I want to thank you for your great work on the channel. You remind me of that time when I visited workshops trying to fight my ignorance. Also, thank you very much for sharing your knowledge altruistically, that says many nice things about you. Some tips and tricks I've seen are the best I've heard since the invention of the wheel... -the carpenter's pencil is my favorite-. I have a 377, 532 - that contact points give me a lot of trouble, anyway is a challenge - and my favorite 582/90... just for the love of old school ROTAX engines. I'd like to commend you for the effort you've put into your project. Congratulations Mr Baker! God bless you!
I admire your continued drive to learn and also the professionals whom were kind enough to share with you. I very much enjoy presenting on my UA-cam channel. My original UA-cam concept was to post topics to assist my customers therefore saving me time explaining over the phone. It just kinda expanded from there. Now if I’ve got something I believe will be of value to someone it hits my channel. It is an honour to pass on my knowledge. I believe passing on information to make the flying sport safer and more enjoyable is a must. Thank you for your kind comments, happy flying!
How would I go about adding a fuel gauge to duals tank set up
Two sender units using one panel gauge can be done with the correct switch. I used an electric guitar toggle switch for three coolant temperature sensors to one gauge. You’ve given me an idea for another video.
Can you also show how to adjust contact points
Next time I’ve got a point 503 in I’ll video the process
@@RotacRepair nice, I’m rebuilding a hirth 2703 with point ignition
Anyways learning. So good to know how it's done properly.
Thank you for your comment and happy you’re now more knowledgeable on this subject.
Great video. How do you ensure the case halves are smooth? No burrs etc
Guess the cleaning video should have been first. Hope you enjoyed seeing the way I clean them.
Has been a while I commented, so I thought I leave one under this video - as always very good work and thanks for the videos and sharing your experience and knowledge, John, all of this is a very valuable additon to the Rotax engine community. Have a good one!
Thank you for the kind comments. As my grandkids always say, “sharing is caring”. Happy flying
Good Episode. THANKS
Thank you, glad you enjoyed it.
Do you have any recommended 2 stroke oil for use in the 503? One that is available at most retailers? Something that is best for engine life, and minimal fouling.
Hi Peter, I use Castrol Super Snowmobile 2T oil in my engine.
Hi Peter. I use Castrol Super Snowmobile 2T oil in my engine.
Hello your videos are so informative I'm commissioning my first Rotax engine,,can you advise please, what type of wire should I use to wire the CHT and EGT sensor wires back to my cockpit pannel please?
Hello, I prefer to use the “jumper harness” avalible from the gauge manufacturer. They are usually available in various lengths making a tidy installation possible. You could use a good quality 18 gauge copper wire too. However the I believe the “jumper harness” is the best.