Rebuilding the Rotax 582 ultralight aircraft
engine.
Inspection
With all the engine parts clean and dry, it is time for a
reassembly inspection. Before putting the engine back together any
worn or damaged parts must be repaired or replaced. This requires
physically inspecting and/or measuring the various engine
components.
Inspection
.-Inspect the piston for signs of wear or damage. Look for
signs of damage to the dome. This could be an indication that
foreign material has entered the engine, or that internal engine
parts have entered the combustion chamber.
Inspect the bottom of the piston skirts. A shiny ring around
the base of the piston skirt may indicate that the cylinder bore
is out of round, or enlarged .
Inspect the ring seating areas, they should be free of
carbon deposits and should not be damaged. The rings once
installed should move freely on the piston.
- Inspect the dowels used to position the rings, for damage,
and make sure that they are not loose.
-Inspect the underside of the piston dome for carbon build
up, and clean if necessary.\..
Inspect piston dome
Inspection
.-Inspect the wrist pin bearing for wear, signs of foreign
material, and or overheating.
-Inspect the wrist pin for damage, wear, and overheating.
-Inspect the connecting rod ends for signs of heat and wear.
-Inspect the cylinder head, for signs of damage. -Check the
cylinder head for warpage.
-Inspect the crankcase halves for damage. Look carefully at
the bearing seating areas. If a bearing has spun in the case it
maybe necessary to repair or replace the crankcase halves.
-Inspect the crankshaft bearings for wear, free play, and or
contamination.
-Inspect the crankshaft key way for signs of wear.
-Inspect the points, condensers, and internal wiring, for
signs or wear, rubbing, or oil contamination. Loose fitting
condensers, oil on the points, or between the condensers and
stator plate, may cause erratic engine performance ..
-Inspect the magneto for foreign material, cracking, and
wear on the keyway.
-Inspect rotary valve shaft for wear, in area of seal
location.
-Ensure rotary valve shaft is straight.
-Inspect rotary valve gear, shim and bearings, replace is
damaged.
Measurements.
..To ensure that the engine parts are not worn past the
point of repair it is necessary to measure the affected
components.
Measuring the cylinders
After the cylinders have been cleaned, all aluminium deposits
removed, and the cylinders honed, measure the cylinder at two
locations. The first across the top of the cylinder 5/8 of an inch
from of the cylinder lip. Measurement north to south, then east to
west.
Then measure the cylinder just above the intake ports, again
measuring across east to west and north to south.
Compare these measurements with the wear limits.
Measuring ring end gap
heat cylinder and rings to 68/70 Degrees F. Using the bottom
of the piston install a ring in the cylinder just above intake
port. With a feeler gauge measure the gap between the ring ends.
Repeat 5/8 of an inch from the top lip of the cylinder.
Measure ring end gap just above intake ports
Measuring rotary valve shaft
To measure rotary valve shaft, support center of shaft,
using a dial indicator measure shaft at both ends and center,
while rotating slowly.
Compare these limits with specifications.
Measuring piston
Heat piston to 68 to 70 degrees F. Then using a micrometer
measure the piston skirt and compare it with specifications .
Replacement Parts -
recommended at 300 hours, or as necessary.
With all parts thoroughly cleaned, it is now time to
reassemble the engine. First replace all worn or damage parts.
-Top Rings
-Bottom rings
-PTO crank seal
-Mag crank seal
-Rubber bearing plugs
-Crank O ring(s)
-NEW CRANKSHAFT
-wrist pin bearings
-wrist pin clips
-Cylinder base gaskets
-Head gaskets
-Intake gaskets
-Exhaust gaskets
-Spark plugs
-Fuel filters
-Fuel lines
-Impulse lines
-Primer lines
-Rubber intake manifold boots
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