BOMBARDIER ROTAX 532 User manual

I

r

I

OPERATOR'S

MANUAL

TYPE 532

eNGtNEs

EQUIPPED

W

ITH

BOSCH

CONTACT

BREAKER

IGNTTION

SYSTEM

AND

BING

CARBURETOR

tlr

t/n

N

Edition:

11

1988

t

JffiT

ffi

BOIvIBARDIER-ROTAX

GMBH

VOTOREI{FAARIK

A-4623

Gunskichen

-

Auslria

rnleron

{O/246'

.rfl.9', rcler

?55dG b'ok d

Ielesranmadresse:

Bonrbrota

x Gu n ski.c he n

Post$scr'ri

Bon'b3de, noru

GorrH F.,[rh

s, A 4021

cu^shrctun. Ao316

-1-

rNDEX

PAoF

truel-oil-nrixture

. . .

2

Break-in

procedure

t

Rotary valve

adjustment

ll

Carburetor

4

Spalk

plug

6

r--ll.l^-.,-lr

!6rrrv^vrrt....!l

AdjuEgnent of

lgnition unit

. . 8

wiring

diagran

9

fgnitlon danping

box

10

Llghllng circuit

....., 1.1

RGrlnd starter

1q

.IaIn lorqllilB

specifl.cations

t6

Fault,-tracing

scheduLe.

18

Liquld-coolinE

systen

.

20

llotary

valve gear

. .

2t

Custonefs Inforratior

1 U

85/E

Zz

'fechnieal

englne

dat,a

Zll

g

:

t.

The ROTAX

enBine

is

a

liquid-cooled 2-strock

engine.

Car:ollu1 an(l

exbensively

tested

Cesign

and

ruBged construction

as

well a6

bhe use

of high

quality

pargs

warran!

naxilrlurtr

reliability

and

durability,

Ititb p.oper

maintenance

and

care

and with

the use

of suitable

fuel

and oi.l

the

engine will.

give you

trouble-free

service

fof nany years.

The ROfAX

design

incorporates

bhe latest

technical

develop-

ments.

In

order

to

take

advantage of

future

developments

we

reserve

the

right

to mal(e

modifications

in bhe

ROTAX

desipn

vlithout

no tice.

FUEL

.

OIL

-

i,IIXTURE

The

RoTAX

engine

is operated

by a mixture

of

standard

grad,e

gasoline

and

-

Super

2-stroke oil

the oi1

lubricatlng

Lhe moving

engine

parts.

Mixing

rabio

fuel

-

oi1

is

50

| 1;

this mixing ratio

has to

be respect

ed,

Too sruch

oit

wiLt

cause

carbon

deposi.,s

on

the spark

plug,

on

the

piston,

in the

cylinaler ports

anal in

the nuffler

and

t{ill

cause probLens.

In

addibion,

bhe

piston

ringsnay

6tick.

If too

little

oil

is

used,

Lubri.cation

witl

be

insufficient,

the

pistonswill

seize

and

the beapings

r.iIl

be damaged.

llote:

Poor

oil quality

cannot

be

conpensated

by

usins

nrore

oif!

o

-t-

BREAX-IN PROCEDURE

Engine

r.

p.

n.

x 1000

Full

The

break-in

has to

be

perforned

with the

engine in the

alr-

frane,

loaded

wi.th

the

prop.e1ler.

Tighten

the

plane

to the

ground

and run the

engine accordinB

to

the following

graphr

10

75

20

l0

12 2

sec sec

nl n

rnin min

1

5

)

5

10

20

l0

lro

50

Tine

(nin)

After

this

procedure

the

idle haa bo be adjusbed.

Then

sbort

take-offs

can

be conducted.

5,5

qr)

4

)

1

Rotary

Valve

Adjus

trnent

2)

In6tallation:

-4-

To

correctly

install

the

rotary

valve

d,isc,

Froceed

as

follows:

-

TurDing

crankahalt

counte!:-clockwi6e

(drive

pulley

side)r

bring

.

EaF[eto

side

Di6ton to Top

Dead

Centei

using^a

T.b.C. gauge.

-

Position

the

rota-ry

valve

disc

on

gear

to have

edges

as

cLoae aE

possi

ble

to

the

Da;ks.

!!!!.,-

The

rotary

valve

disc

trJ positioning

each

side

of

rnsEArtatloD

po

si tion.

i6, aayEmetrical,

therefore,

at assedbly

oLsc

on

gear

to determine

best

CA

N BURNTOR

The

BING

carburetor

is a

piston

type

carburetonith

float

chanber.

The

carburetor

can

be adjusted

by

jets

and

adjusting

screws.

Changing

of

jets

should

only be done

by a Bpecialist

or

after

consulting

the

engine

nanufacturer.

Tbe

air-fuel

nixture

at

idle

Epeed

is adjusted

by the

air

adjusting

screw

(see

itl.

no.

28).

The

idle

r.p.m.

is

adjusted

ment

screw

(iI1.

no.

l0).

by the carburetor piston

adjust-

The

carburetor

rnust

be in an

exact

right

angle

position

in

relation

to

the

crankshaft

in

both views

from'top

and

froro

the

intal(e

side

to

ensqre

an equal

nixture

distri_

buti.on

to both

cylinders.

Take

care

that

end

of both

venbilabion

tubes

(i11

no,

J1)

are

protected

from

e xcessive

airst

re

an.

l,lote

:

-5-

qf!G-Clrburetor

IJ

-----1

|

44

5

4

1.r l1

'"u

.^t

tz-tl

|.)-

It

r:J

B

,.9

A

13--

,,/Y

40-

qo-.0

t6_

r,.,1

H

17

_iA

._6

l6

-Nl

<3

re

\:_),.

21

24

25

32

1

-6-

STARTII'IG

TIIE E}JGIIIE

On cold engine uae choke.

Don't

6el thro tt

le.

Starl

the

engine -

Ifter the

first

i6nitions open throltle and ohor"tly after

c106e choke.

Attention:

ThrottLe opening

reduce6

the effecl of the choke.

If the engine is started too

long

wittl

the

cboke,

the

engine

gets

flooded

vrith

fuel.

If this

happens,

the

apark

plu8s

bave

to

be

unscrewed,

cleaned, dried

and the

engine has

to

be

started

(cranked

through)

several tjincs-

lf the

engine

still

does not stari, see

chapter

"FauLt

Tracing Schedule

,

SPARI( PLUG

If the engine fails to

start or operates

only

on

one

cylinder,

it shoutd

be

checked whether

the ignition

$iring is disconnected

fron the

sparl(

plug proteqtors

or fro[ the spark

plugs.

Then

the condition of

the spark

plugs

has

to be cbecked

(bridged

betveen

the

electrodes,

oily,

sooty

etc.).

If the

spark

plug

heat range

and the carburetor calibration

are correct, the

spark

plugs

logk brovrnish.

With

too high

heat

range

(cold

plug)

anal too rich carburetor

cali.braiion

they

look black

and sooty.

lJith too

IoN

heat

ran€e

(ho!

plug)

oa

too lean carburetor

caLibration

the

spark

plugs

are butrt

white and the

electrodes

are covered wiuh rneLt

drops.

ATTENTION:

lleavy oil

deposits

on tbe efectrodes and insulator

cause

engine

troubles and have

to

be removed

regularly

(every

10 hours

).

If

no

and

even

after

cleaning

or changin6 thc

spark, the

spark

plug protector

and

finall.y the

ignition

unit Ehould

be

spark

pluB

t

lrcre

is

the

ignition

cables

checked,

ICNITION UNIT

The

RoTAX

cngine

is equipped

with a

BOSCH

maEneto generalor

12V

140',

producing

the current necessary

for

the spark,

The

ignition

unit

has been

set most carefully

and

precisely

by

the

factory, l'lake

no

cbanges unless

absoluteLy

nec.essary.

In case

of troubles observe

the

follouinE:

Il the ignition fail,s inte!'nitbently

or

.if

there are

other

troubles that

a.e

due

bo neither spark

plug

no.

jets

nor

carburetor,

the ccntact breakers

may

be the

cause.

ContacLs r0usl be

clean

and must

noL be burnt,

llith

new

engines

the

car,r-foll,o$rer

of

the

contact breaker

nust

sbj.Il

adjust it-

seLf. Re-set'"ing of conLacts r0ay tfrerefore be necessary

after

some

tine.

Tire

bi'ea]<er contacts are

accessibfe after rcmoval

of tire rewind starier and the starting

pu1ley.

The

hagneto

housin6 need not be remo\ted.

To

check whethe!'tbe

ignition timing is correct

t)rere is an

arron on

the crankcaseJ Further

there

is a nark on

the

magnello

housing- At

the

rtronent

of ignition

(i.e.

when breaker

conLacts

open,

check with test lalnp,

buzzer

etc.' conneclted

to

shorting

cabl,e

of

the

respeElj-ve

cylinder and to mass),the

marl(

on the nragneto

houaing

rnust coraespond witb

the

arrow

on

the

crankcase.

8-

ADJUSTMTI'IT OF IGNTTIOI,I TII4ING

The ignition tirning is

adjusted

after loosening the

fixing

screw G next to

the adjusting

groove

H

(see

wiring diaErarl),

so thab the contact breaker starts

opening when the

piston

is

1,96 nun

(18o)

B.T.D.c.

Chect(

witlr test lajnp or

buzzer

as described

before. llhen

cranking

the

engine, the breaker

contacts

nust

open

0,10:0,40

nn

(0,012:

0,015

in).

rf this is not the case,

turn the stator

plate

and

repeat the above

procedure.

POLE SHOE GAP

t{hen

correcL timing is

achieved, check

pole

shoe break-away

gap.

The

gap

must be within

13-17

mm ot .51

-

,67

i.n,

(see

illustration) when the mark on flywbeel corresponds

with nark cn fan housinE.

If bhe break-array

gap

is

out

of

tolerance,

the

flywbeel

may

have burned

on

the

crankshaft. Redove flylrtleel and inspect

taper

and

key. Repair

if

necessary.

"b9

$"

"ag"

),,/,1

)'<

o

qardboard

strip

nagnet

Tining

adjusgmeno and

repair

of

iEnition unit6

6hould

hest

be left to

a

skilled Jnechanic,

lnproper handlinE can easily

cause none troublea Hith

such

delicate

parts.

IIIRINC DI AGRAM

Particular

care

cable6

(J)

and

to the

i8ni

t

ion

has to

be taken

the

rDaEs c

abl es

coils

(A),

6ee

that the ignition

generaior

(

l'1) be correctly connected

illustration.

o

(Po?er

Talre

oft)

o

PTO

A

c

D

E

Il

c

J

K

L

tt

t,l

o

l1A0

ignition coi.ls

generator

coil

(

bottom

Iighting

coil

l0!r

(top)

lighbing

coil

110i1

c

ondenser

contact

breaker

lever

breaker

contagt

s

fixing scren

adjusting groove

generator

cable

s

shoating cab

1es

naas

cables

ignition

cabfes

spark

plug protectors

To

cub

off the

ignition,

the

c onnect

ed togelrLer

and/or

to

2 shortinE cables K

have

Lo

ground.

bl.^'.:k

be

it'-

IC'.IITION

DA14PI'JG

BO):

To

prevent

piston

failurea

causcd

by

gloNing

spark

plugs

(due

to

certain

fuel

additives)

of deposit6

on

it is

nec

es s ary

bours

of

opera-

a) to

clean

the

spark

plugs

every

approx.

10

tion

or to

replace

thern.

b) An i8nition

danping

box,

part

no. 866

572,

is nounted

on

the

engine

to

reduce

the

Epark

energy and

the

glowing

of

the spark plug

deposits.

r.llRrl'lc

prAcRAM

FOR

r{OUNTIN0

I0NITION

pAJ,1ryNC

BOX

865

572

red

cable

to magneto

side

iqnition coi1,

conne4tion

1

black

cable

to

p.t.o.

side

ignition coil,

connection

15

black

mag.

side

ignit ion

coil

DampinR

box

check

a)

orecaution

checki

Connec

!

There

nusb

.be

ng spark

on

If there

is still

a spark,

T

I

P.t.o.

side

ignition

coi I

darnping

box nith

reversed

polarity.

both

pluqs

Hhen

cranking

the engine.

the

damping box

is defective.

b)

in case

of

ignition

troublea

(no

spark):

Disconnect

dann

ing

box,

j.f

there

is

now

a sparli,

!be-

!9

!-r9!i!c-9!!9q:s9gr9

99_g!9 _p99 c!qlc!

1)

Danping

box

defect

or

reverse

connected

(see

a))

2;) Fcrle-ring

l)reak-away

gap

out of tolerance

(defecti.ve

;loodrtrff-key

or

lrrong

armature

plaie

adjuEtnent

(

see page

B)

damping

box

865

5Zz

j.f

there

is

now

a sparli,

-

11

-

LICIITI]IG CI RCUIT

The

BOSCiI

magneto

6enerator

produces,

apart fron the

electric

current

required for the

ignition,

12V

1ll0W alternati-n8

current

which

can

be

directly

used

for

feeding liglrt6 artd/or

olher users tbat

can be operated

vrith

alternating cu..en!.

To avoid the voltage

to

rise above

pernissible

1eve16,

either

users

arnounting

to 1q0 watts

have

to be connecied,

or a

vol-

tage regulator

has to be

used.

To operate users

requi.ri.ng direct current

(e.9.

battery), a

rectifier-regulator

is

required-

A rectifier-regulator,

part

no. 866 080, is avaifable. For

feeding

l:ights

on1y,

this rectifier-regul.ator

can

also be

used

without

battery. In

tbis case the regulaLed

RHS

voltage

will

be between

11 ard 12 Vol.ts

as long

as a mininum

load

of

1 anp is

provided.

In case of

a baitery

it has to be capable

to absorb apprcx.

1amp. ninimunr

continuous

charging load, even

with

full

bathery

(suGBested

r4in.

battery capacity:

9

anp,h). ReBulated

voltage

is 11.5

to

1it.5 vol.ts.

-

12

-

ll'Inttc-DIncRAfl

FoI

nscllFtEn-REGULAE'i

866 o8o

h a cilculr

vithout

bdrtcry

1n

conjuncrion

rirh

a balrery

I{IRINO

DTAGNAI'I

FON

ELECTRIC

STARTER

fus?

151

electric-sta!ter

},IRING DIAGNA

(not

1im!ted to

FON RECTTFIER-FECULATOR

25It 870

minioun

of

1 Ampere

consumption)

IInINC

DIlclnl

FOll IIECIIFIEn-.caolaror

25!

8tO

ln r clrcult vlthoor

b{tr.ry

!

(<

I

-l-'

..r1!11v.oaruo.r'!

tIlIltC

DIiCnl8 FOn RECTIFIEn-..guletor 26!

870

(ln

conlun.tlon

!1th

a eondcn3or 2000

uF)

20OO

!F

IiIRING DIAGRA'{ FOR RECTIFIER-REGULATOR 261 870

in cotrjurction

vith

r b.ttert

CD

-T-

I

3

-

14

-

T.IIND STARTEN

Pull starter

grip

out slowly

until

resistance is felt,

tlren

pull

out vigorously

but not fully up to

the

end. As far as

possible

puU

in

the

direstion

the

rope. comes

out of

the

sheave. By a rewind

Epring

the

starter

grip

returns to its,

original

position.

Don't

let

the starter

grip

fly

back.

Do

not

operate

the engine

if the rewind

starter

is defective.

?\.

I

C}IANOII{G

TIID SfARTER

ROPE

('Ihe

numbers

stated

in brackets refer

to the illustration)

First

remove snap

ring

(9),

loop spring

(B),

circlip

(7),

pa!.rL

1ock

(6)

and the

pawl (5).

Tools;

Snap

ring

tongs

screNdriver

a\

l@)

-l

2

@

i

5

roJ)

\,/

0

OB

_

15

_

PulI

out the starter rope

fully

to thc end,

hold 6tartc.

housinB

(1)

and rope Eheave

(J)

togethcr in

tbeir

position.

Tlrere

ia

an opening

in the rope. sheave.

The key clamp

(lt)

visibl,e

in the

openinB

has

to be

pushed

out

ln

the opto6ile

sense of tbc

pslling

direcbion-

Pull

the rope out.

of the

rope

Sheave.

Then insert

the

new starLer rope into ttre

rope

aheave,

rDount

the key clamp

in

the

same

position

as it

was

before

and remount

the

parbs

5,

6,

7,

I and

9.

cautionl Do not

rernove spring container

(2),

this

might

cause

injuries

l

-15-

DI'CAIIBONI

ZING

After approx.

50

hours

of

gse

the cornbustion

chanber should

be de-ca.bonized.

io do so:

Renrove cyllnder

heaal.

HoId cylinclere in

place

by suitable rneans. Ueing a scraper,

the carbon scales

on

the co,nbustion

chamber

of the cylintter head

and on the

top

of the

pision

should be rer,roved.

Piston

at top dead

center.

I.IAIN TORQUII,IG

SPEcIFICATIONS

cylinder head nuLs t{8

Cranl(case

gcre*s

I,16

l,1g

l,la8neto housing

nut,

(1122

x 1,5)

Crankcase nuts

(or

-sqrevs)

1,t10

Exhaust

manifol<l

screws M8

18izt

8+10

18i24

80+90

Nn

+

in.lb

160

+

210

lo

+

88

760

+

21O

Z1o

+ 8oo

t2o

+

t54

160

i 210

JO

18

4o

2l+

-

18

-

FAULT-TRACING

SCHEDULE

bh--

engine difficult

stari?

1.

Too rnuch

use

of starter

2.

Faulty

ignition systen

J.

fncorrect

fuel

mixture

yes

DO

no

+

open the fuel cock

1.

Gasolj.ne tank

enpty

2.

Blockage in

tank cap

J.

Blockage

in

fuef

cock

q.

BrocKage

Ln tuet lrne

5.

Needle valve

blocked

Does

gasgline

reach

the carbure tor?

1.

Blockage

in c arbure

tor

Does

gasoline

reach

Probable

tault

1.

Floab

stuck

2.

Float

leaks

J.

NeedLe valve

does not

ea. f hF^^ar] rr

Does

the carburetor

keep

flooding?

Has

the

engine

becotne

wet r,rith

fuel ?

fs tbere a

spark at the

spark

plug protec

tor?

1. Poor contac!

betrreen

ignition coil. and

igrit

ion

cable

2.

Ignition cable

broken

or

cr.^F|-^in^!!i+iF'

J.

Fautty ignitj.on coi

I

Is

there a

spark

a.t

the spark

plug?

1. Electrode

gap

too Large

2. Briilging between electrodes

J.

Insulator

broken

or wet

4. spark

plug

oily

Change the spark

plug

1. Faulty ignition tining

2.

Float needle does not seat

properly

,.

Air

cleaner blocked

tl.

Faul.g

in

carburetor

5.

Defestive

spark

plug

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BOMBARDIER ROTAX 532 User manual

BOMBARDIER ROTAX 532 User manual

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