All information here is correct at the time of publishing to the best of our knowledge, but Rotax recommendations may

change at any time without

our knowledge. It is the engine owners responsibility to ensure that the engine is fit for flight at all times. The information is provided here free of
charge and with no obligation from us to the consumer.

CONAIR SPORTS
ROTAX 2-STROKE MAINTENANCE SCHEDULES
The following maintenance is planned and necessary for Rotax 277 UL, 377 UL, 447 UL SCDI,
462 UL, 503 UL, 532 UL, 582’90 UL and 582’99 UL, 618 UL.

X Rotax recommendation Example at the end of

Carried out as part of ConAir Sports standard service packages the routine
Service available at extra cost maintenance tables

First Every
Details 2 10 12.5 25 50 75 100 125 150 175 200 225 250 275 300 5
h h h h h h h h h h h h h h h y
1 Replace carburetor rubber(s) X
2 Replace radiator hoses X
3 Replace cable grommets X
4 Replace cross shaft oil hoses X
5 Ground run (if installed) X
6 Level check of liquids X
7 Re-torque cylinder head nuts (1) X
8 Re-torque exhaust manifold screws (1) X X
9 Check rewind starter condition
10 Check rewind starter rope (10) X
11 Check electric starter gear X X X X X
12 CCBCT check
13 Inspect spark plugs (10) X
14 Replace spark plugs X X X X X X X X X X X
15 Check ignition system X
16 Check and/or adjust ignition timing X X X X X X
17 Check security of condensors X X X X X X
18 Check condition of points X X X X X X
19 Check condition of generator coil X X X X X X
(points ignition engines)
20 Replace points & condensers X
21 Replace generator coil
22 Check operation of damper box X X X X X X
23 Check & clean inside spark plug caps X X
(10)
24 Checking of V-belt tension X X X X X X X X X X X X
25 Lubricate ball joints X X X X X X X X X X X
26 Replace exhaust muffler springs X X X
27 Lubricate control cables (3) X X X X X X X X X X X
28 Check propeller balance and tracking X X X X X X X X X X X
(2,3)
29 Inspect propeller mounting bolts (3)
30 Clean and oil air filter X X X X X X X X X X X
31 Check fuel filter X X X X X X X X X
32 Replace fuel filter X X
33 Check carburetor(s) and re-adjust (idle X X X X X X X
speed, cable tension…)
34 Clean carburetor(s) and check for wear X X X X X
35 Replace jet needle and needle jet X
36 Inspect carburetor needle X X X X X X
37 Check fuel pump (measure fuel X X X
pressure)
38 Check gearbox oil level X X X X X X X X X
39 Replace gearbox oil X X X
40 Inspect rubber coupling X X X X X X
41 Re-torque gearbox backplate bolts (A X X
type gearbox only)
42 Check and adjust gearbox, preload of X X
springs (type A & B type gearbox)
43 Check cross gear oil X X X X X X
44 Replace rotary valve lubrication oil X X
45 Inspect cylinder head and piston crown X X X X X
(4)
46 Inspect piston rings for free movement X X X X X
(5)
47 Check piston diameter (7) X X X X X
(6) (6) (6)
48 Piston ring: check gap (7,11) X X X X X
(6) (6) (6)
49 Piston ring: check axial clearance X X X X X
(rectangular ring) (8, 12) (6) (6) (6)
50 Check cylinder diameter (7,11) X X X X X
(6) (6) (6)
 2 10 12.5 25 50 75 100 125 150 175 200 225 250 275 300 5
Details h h h h h h h h h h h h h h h y
51 Cylinder: check for roundness (7,11) X X X X X
(6) (6) (6)
52 Remove, check and de-carbonise rave X X X X X
valve (618 UL only)
53 Replace cylinder head gasket, cylinder X X X X X
base gasket and exhaust gasket (8) (6) (6) (6)
54 Inspect piston pin and bearing X
55 Inspect crankshaft and replace outer X
seals if necessary
56 General overhaul of engine (9) X

Notes:
(1) and after every replacement of gasket(s) (7) wear limit see Service Information 5 UL 91
(2) also after any damage (8) If cylinder has been dismantled
(3) according to instructions of manufacturer (9) To be carried out every five years or every 300 hours whichever comes
(4) if carbon layer is more than 0.5mm thick, decarbonise first. Contact authorized distributor or service center.
(5) if piston ring sticks clean and replace if necessary (10) To be examined after every 12.5 hours of operation
(6) if used in very dusty atmosphere (11) Necessary only if piston rings are not freely moving

GEARBOX SERVICING
The following maintenance is planned and necessary for Rotax Gearboxes
Details 100hr gearbox 100hr gearbox service Re-torque T/L
only fitted to engine bush
A B A B C E C E
1 Remove propeller X X X X
2 Drain oil X X X X X X
3 Remove gearbox X X
4 Measure & adjust pre-load of shock absorber X X X X
5 Re-torque back-plate mounting bolts, remove, replace & re-loctite if X
necessary
6 Inspect rubber coupling X X X X
7 Remove gearbox front X X X X
8 Remove main gear X X X X X X
9 Visually inspect gear and shaft X X X X X X
10 Visually inspect taperlock bush X X
11 If applicable replace massive washer X X
12 Re-loctite taper lock bush and re-torque X X
13 Re-assemble including new gasket if necessary X X X X X X
14 Re-fit gearbox and propeller X X X X
15 Refill gearbox oil and wire lock X X X X X X

Example:
A 503 on a Quantum that has done 400 hours should have had:
10 hour engine service and 10 hour gearbox service after the first 10 hours
50 hour engine service at 50 hours Total Time
100 hour engine service and 100 hour gearbox service at 100 hours Total Time
150 hour engine service at 150 hours Total Time
100 hour engine service and 100 hour gearbox service at 200 hours Total Time
250 hour engine service at 250 hours Total Time
300 hour engine overhaul and 100 hour gearbox service and replace all rubber parts at 300 hours Total Time or 5 years old
50 hour engine service at 350 hours Total Time
100 hour engine service and 100 hour gearbox service at 400 hours Total Time

SHOCK LOAD TESTING

The following is necessary for Rotax 2 stoke engines after a propeller strike (SLT)
Details Engine Gearbox Type
277 377 447 462 503 532 582 618 A B C E
1 Visual check of engine X X X X X X X X
2 Where necessary remove and re-fit engine X X X X X X X X
3 Removal of flywheel X X X X X X X X
4 Check crankshaft radial run-out mag end X X X X X X X X
5 Check crankshaft radial run-out PTO end X X X X X X X X
6 Check crankshaft phasing (180) X X X X X X X
7 Check flywheel woodruff key X X X X X X X X
8 Refit flywheel X X X X X X X X
9 Check ignition timing (points ignition engines) X X X X X X
10 Remove propeller and strip down gearbox X X X X
11 Visual inspection of housing X X X X
12 Measure radial prop-shaft run-out X X X X
13 Measure axial prop-shaft run-out X X X X
14 Remove gearbox front X X X X
15 Measure & adjust pre-load of shock absorber X X
16 Inspect rubber coupling X X
17 Remove main gear X X X X
21 Crack test gear set X X X X
18 Visually inspect gear and shaft X X X X
19 Visually inspect taperlock bush X X
20 Re-loctite taper lock bush and re-torque X X
21 Replace serrated washer with latest type as required X X X X
22 Reset pre-load on shock absorber X X
23 Replace gearbox gasket and refill with oil X X X X
24 Install propeller as necessary X X X X
STORAGE CHECKS
These checks do not include the routine maintenance that needs to be carried out when the engine is installed, such as oil and filter change,
changing of spark plugs, coolant change, balance carbs or compression tests.
Storage Period
> 12 months > 12 months > 5 years
Work Required < 5 years < 5 years Rotax specify that an overhaul is required at this time, but
(engine turned at (engine not turned if the engine is found to be in good condition and you are
least every 3 at least every 3 happy, we will carry out a reduced inspection to establish
months) months) the serviceability of the engine.
Top end strip down and inspection   
Decoke   
Drain cooling system and flush, remove water pump   
housing and refill fresh
Strip & clean carb   
Check timing   
Check spark plugs and caps   
Where applicable check points and condensers   
Check starter   
Remove flywheel and inspect for corrosion   
Inspect fan belt and pullies   
Strip & inspect gearbox   
Where applicable change oils (cross gear and   
gearbox)
Check exhaust system & lubricate ball joints   
Replace exhaust springs   
Clean or replace air filter   
Strip & inspect fuel pump   
Operator to carry out CCBCT checks every 10 hours   
Replace oil seals on crankshaft cross shaft  
Complete strip and inspection of engine 
Change all rubber parts such as hoses, crankshaft 
oil seals, fan belt, carb rubbers, water pump seals.