Bombardier-Rotax 462 User manual

''!
t
a
o
iI
OPERATOR'S MANUAL
TYPE 462 ENGINES
EOUIPPED WITH
BOSCH CON
TACT- BREAKER
IGNITION SYSTEM AND
BING CARBUBETOR
-1,.
f,
N
IEdition Okt. 1986
.j
BOMBARDIER.ROTAX
GMBH
MOTOBENFAgRIK
A-4623
cunskhchen
- Austria
Telelon:
{07246)
2tl-O'. t€ler: 25546
broka
T€legrammadr€$o: Bombrotax cunsXirc-hen
Fodlrtck l. Bonb.di.rnob G6bH,P@d*h s,a-4623
Guneki.rh.n.
a6ti, @ffi

-7-
BOMBARDIER.ROTAX
GMBH
MOTOBENFABRIK
A-4623
Gunskirchen*
Auskia
Telelon:
{O
7246)?71-O',
Teler'25 5a6bom'ot.
I€leg.ammad.esse: EombrotarGunsknchen
De
scription i
Cylinder:
Bore and Stroke:
Compression
Ratio:
Dj.spLacenent:
Ignition Unit:
fgnition Ti.ning I
Contact Breaker
Points Gap:
Break-away Oap:
Spark Plug:
Rotary Va1ve:
Rotary Valve
Tlning:
carburetor:
Fuel Punp:
Starter:
Fuel :
Lubt'ication:
WeiBhts:
r.f,.s'!
\?./
- r,^O .-^-
=120- BTDC
= 51: ATDC
:140- BTDC
Engine Data Type ROTAX452
Two-cycle,
_
two-cyl inder rotary valve engine,
oit-tn-fuel tubrication, liquid_cooLed iith-
lnregrated pump
2 light alloy cylinders with cast-iron sleeve
69,5 runx 61 mm
tLt)
\62,8 c.
c.
BoscH-flywheel rnagneto-generator SCpz 12V 14OW
1,86 mm
(1Bo) B.T.D.c.
0,1 nn - 0,4 nrn
UL
Bmm-17nm
BSES
tow performance execution 924 202
High perlormance execution i24 205
Lowperformance execution 4,= L77o, ctosee p
opens 7
High performance execution/= 147o, closes /?
opens /
See illustratlon page 4
BINC'6
MIKUN
I
Rewind sbat'ter or electrj.c atarten optional
0asoline, octane number
not below MoN
gl or
Super-two-atroke-oil; rnixing ratio 1 : 50 (2
Engine without carburetor, radiator and fuel
uarouretor with rubber f.lange and cLanps:
Exhaust system with screws:
29 ll/.r.9
kt,,
at 55oo
rpm
(5?
d (A) ver:sion)
)z nrl ta kw at 6500 rpn (uS-versi.on)
ot
o
I
9U
RoN
90
punp:
26
o'95
5
,90
kg
kg
kB
Perfonnance i
Septenber 1984

-2-
GENERAL
The RoTAX englne Ls a liquid-cooled 2-stroke engine. careful and
ertenslvely tested deslgn and rugBed constructlon aa uell ea
tbe use of high quality parts warrant naxir0uE rellablllty and
ilurability. $ith proper Daintenance anal care and ul,th tbe u8e
of suLtable fuel and oil the engine xlll give you tloub1e-free
aervice for nany years.
Tbe RoTAXdeeign Lncorporates the lateat technical develop-
lrenta, In order to take advantage of future tlevelopnenta we
reaerve the light !o Dake tlodificationg in the RoTAX
design
ritbout notice.
FUEL-OIL-MIXTURE
The ROTAXengine is operated
gasoline and
- Super z-stroke oil
by a nixture of atandard grade
the oil lubricating the Doving engine parts.
ixing ratlo fuel - oil ls 50 ! 1; this Dixing ratio haa to
be respected.
Too Duchoil will cause carbon deposits on the spark plug,
on tbe piston, ln the cyLinder ports analin the nuffler and
xill cause probleros. In atldition, the piston ringsnay 8tick.
If too littl.e oi1 Ls used, lubrication will be insufficient,
the pistor|8sill seize and the bearings xiII be danaged.
Poor o11 quality cannot be compensated
by using nore oilt
€
Note I

BREAX-IN
PROCEDURE
The break-in ha6 to be perforEed wlth the engine ln the air-
frane, loaded ith the propeller. TlEhten the plane to the
ground and run the englne accordlng to the following graph:
6ec 6eg
-1-
6ec l0 aec 2
rnin
Ensi ne
x 1000
FuIl
\,5
rnin rain
10
After this procedure
Then short take-offs idle has to be adjusted.
be conducted.
50
50
lr0
]0
20 'lrhe
(nin)
the
qan
111'la1

-4-
Rotarv Valve Ad.iustme
nt
Installation r
To correctly install the rotary valve disc proceed as foIIowEi
- TurDing cralkghaft couater-clock$rise (drive pulLey side), blinB
naRpeto side Di6ton to 1'opDead Center usilg a T.D.C. gauge.
- Position the lotary valve disg on Eear to have edges as cLose aa
pos6ible to the Eaxks.
NOTE:
The ro bary valve d,isc iB asJrDmetrical, therefore' at asseDbly
E$lositioning each side of disc on gear bo def,ernine best
iDstallation position. see also page no. 2'l
CARBURETOR
The BING carburetor is a
charlber. The c
arburetor
acreus. Changingof j ets
or after consulting the
piston type carburetor
can be adjusted by jets
should only be done by
engine ,nanufacturer.
with float
and aqi ust ing
a speclalis t
The air-fuel nixture ab idle 6peed is adjusted by the air
adjusting ecrew (see il1. no. 2B).
lhe idle r,p.n. is adjustecl by the carburetor piston adiust-
nen! screw (il,l. no. l0).
The carburetor must be in an exact right angle Positj.on
ln relation bo the cranksbaft in both views from top and
from the inbake side to ensure an equal nixture distri-
bution to both cylinders. Take care that end of both
venbilation tubes (i11. no. ,1) are protected from
exceasive airs tream.
t'-"'t.'",a\
>\ ^\
7Zz'h.
't,'Z,+ffi,
'aZ/ZiVD
'4t%
Note:

-5-
fl
tz-1 @r .^
E Ll-- ru
11
-s ";'
f)\
t, ', .4e
eD'
e
a
7-q t
at
FI
e:
o-1ll!Jd
\JII' d
"1.'l
tl
39
I
I
(3
n
-----1-l
t€r
st
-E E
FI
oo--$\sa
\1
e\l
ll41
142
BING-Carburetor
ro---t I
11
35
38
34
37
'.
fl
3
12-B
6-
il-
U
a
E-
E
E
s3€
32c c--i
F-'
tl
!
2S 50
%-3o
43 re
\J,U
21
24
25
+aE
{_,;;

- 6-
STARTINOTHE ENGINE
On cold engine use choke.
: Don't set throttle.
Start the engine.
After tbe firat ignitlons open throttle anal ahortly after
sloae choke.
. Attentlon: Throttle opening reduces the effect of the choke.
If the engine iE started too long rJith the choke, .the englne
gets flooded rith fuel. If this happen8, the.spark-p1uga
have to be unacleueal, cleaned, dried aDd the engine haa to be
starteal (cranked through) aeveral tinea. If the engine Btill
doe8 not atart, aee chapter nFault Tracing Schedulerr.
SPARI(PLUG
If the engine fail.s to atant or operateE only on one cylinder,
Lt Ebould be checked whether the ignition wi.ring is disconnected
froD the apark plug protectors or fron the apark ptuE6. Then
the condition of the spark plugs has to be checkeal (bridgeal
between the electrotles, oily, sooty etc.).
If the spark plug heat raage dnd the carburetor calibration
are correct, tbe apark plugs Logk browniah.
Yith too higb heat range_(col.al p]ug) and too rish carburetor
calibration they look bLack and sooty.
Uith too low heat range (hot plug) or too lean carburetor
calibration the spark plugs are burnt white and tbe electroatea
are covered with nelt drops.
ATTENTION:' Heavy oiL deposits on the electrodes and insulator
cause engine troubles and have to be renoveal
regularly (every 10 hours
).

ff evenafter cleanlnE or changinB
the
no Eperk, the apark plug protector and
anatflneuy thc ignition unli Ehould be
Bpark
pluB there ls
the lgnition cableg
checked.
IONITION UNIT
.The RoIAX engine la equipped aith a BoSCInagneto Senerator
12V 1q0W
proilucj.ng the current necesaary for the 8park. Thc
ignltlon unit hae been set rDoEtearefulfy snd Ptecl8e1y by
the factory, I'take no ebangea
unless absolutely necessary.
In case of troubles observe the follolflng:
If tbe lgnition failE Lnternittently or if there are other
troubles that are due to neither spark plug nor Jets nor
carbuletor, the contact breakefs rlay be the cauac.
contacta tlust be clean antl Dust not be burnt. WLth ner engineE
tbe can-follower of the contact breaker tlust Bti1l adiust it- i
ae1f. Re-setting of contacta Day thelefore be nece68ary after
soDe tiDe. The breaker contacts are accessible after reDoval
of tbe revind starter anil the starting puuey, The Dagneto
hou3ing need not be rerDoved,
To check hether the ignition tioing is correct there is an
arrou or! tbe erankqase. Further there ls a nark on ihe
nagneto housing, At the nonent of ignition (i.e. uhen breake!
contacta open, cheek with test lamp, buzzer etc., connecteal
to shorting cable of tbe respective cylinder and to nass)rthe
Dark on the nagneto houaing Dust correspond with the arlow
on the crankcase.

8-
ADJUSTI'IEI'ITOF lCNITIoll TIMING
The ignition timing is ailjusted after looBening the fixing
asrew C next to the adjusting groove H (see wiring diagran),
so that the contact breaket atarts opening when the pi8ton
18 1,86 nn ('18") b€fore T.D.O. --, ,- 1 . I,
Check with te6t lanp or buzzer a6 described before. llhen
cranking the engine, tbe breaker contacts rnuEt open
0,10.0,q0 run (0,012 i 0,015 in). If this iE not the caae,
turn the staior plate and repeat the above procedure.-
POLESHOECAP
Iiben correct tlnlnA tE achleved, sheck poLe shoe bneak-away
gap. The
gap nust be vltbin I to 17 rutr
o? O.J to 0.6? in,
(see lllustratLon) xhen the nank on flywheel cortreaponda
rith nark on fan housing.
If tho break-away gap 1! out of tolerance, the flywheel nay
have turned on the qranksh&ft. Renove fllr$heel and LnBpect
taper and key. Repair if neceasary.
tw
eag.-
),''1f S
K
cardboard
oe shoe
nagneE
strip

.9-
Timing adjustment and repair of ignition unit6 should best
be Left to a skilled nechanic. lmproper handling can easily
cau8e more LroubleE with such delicate parts.
WIRII{GDIAGNAM
Particular care
cables (J) and
to the ignit ion
has to be taken that tbe ignition generator
the nasB cables (M) be correctLy connected
coils (A), Eee illustration.
o
(Power Take
off)
A
B
D
H
J
K
L
I,I
N
o
r6rrrvrvrr uvr r.
generator coil- (
botton )
lighting coil lol,I (top)
lighting coil 110l,J
condenser
contact breaker lever
breaker contact s
fixing screrr
adjusting groove
generator cables
shorting cables
lighting cables
nass cabl.es
ignition cables
spark plug prot ectors
To sut off the ignition, the 2 shorting cables K have to be
connectedl
together and/or to ground.

IOIIITIOIIDAMPINC
BOX
To prevent pi8ton failure8
8park pluEs (due to certain
a) to clean the Bpark plugs
tion or to repLace thern,
An ignldlon dampingbox,
the englne to reduce the
the apark plug depoElts.
cauBed
by glowlng of depo8it6 on
fuel addltives) lt ls necessary
evary approx, 10 hours of opera-
part no. 866572, L8 rnountealon
spark energy anri the glowing of
b)
XIRINC DIACR,'M
TOR
II'OUNTINO
ICNITION DAI'IPINCBOX
865 572
- red cable to rnagneto
side ignition ioiL, connection 1
- black eable to p.t.o. side ignition coi1, connection
15
T
I
P.t.o,
gide
ignition
cDil black
nag.
side
ignition
coil
danping bor( 856 5?2
Darnpingbox check
a) precaution check: Connect danping box r{ith reversed polarity.
There tnust be no spark on bolh plu8s when cranking the engine.
If there is etill a spark, the damping
box iB defective.
b) in ease of ignitLon troubles (no spark): Disconnect danplng
box, if there i9 now a spark,
3hq-IellgEisc-srr9r:!eu!9es_ere-p9e
9i!le!
1) DanpinC
box defeet or reverse connected (see al)
2) PoLe-ring br:eak-away gap out of tolerance (defective
Woodt'uff-key or wrong arnature plate adjustment
(see page 8)
I
li

- 1t -
LICITTIHCCIRCUIT
Thc BoscHDagneto generator producea, epart from the electr:c
current regulred for the lgnltlon, 12V 1ll0!lalternatlnB
current Ehlch can be directly ri6eal
for feeding llBbts anil/or
other u6era that can be operatcd wlth alternating current.
'to avoid the voltage to rlee above permiosible levelE, el,ther
users aBountlng to 140 xatts have to be connecteal,or e vol-
tage regulator bas to be uBed.
To operate usera requiring alirect current (e.g. battery), a
rectifier-reguLator is requlred.
A rectifl.er-regulator, part no. 866 080, La available. For
fcealing light8 only, thia rectifier-regulator can also be
uaeal
rithout battery. In thl8 case the regulated Rl'lS voltage
iI1 be between 11 anal 12 Volts as long as aJ&iJliJIIutlLf-ggE
of
1 alp iE provided.
In caae of a battery it has to be capable to absorb approx.
18.np. nininuD continuouE charging load, even with fuLl
battery (suEgeatednin. battery capacity: 9 a.np.b), Regulated
voltage is 1J.5 to 14.5 volt6.

' IZ '
vISIlC-plrClr FoSEECttp:En-nEcuLlToR
866 o8o
Ln r cl!.u!! !!!!9!i brrt.!,
rrRrxc Dllona toi nEc?ItlE8-nEculllon 866080
iD 6onjunc!1on
!!g! r b.tt.!y
rIRINO DIACRAI'I
PORE',ECTRICSTARTER
fur. 151
T
.I.clflc-.ta.r.r

IIIRIIIC DIAONAM
(not llDltcd to
- 11 -
FONNECTIFIER-REGULATOR
264 8?O
tDlnlnun
of 1 ADperecongumplLon)
tllllxc DIlCirx FonIECTIFlEi-..tolrtor-261 870
ln r clrcutt rltbou! brrt.rt
l/bl.ck
I aF r
-r- ...11!tv coD!u!!!!
(only,
tt8ItlG DItoRlUFonl8crMEr-rcauI!lor ?51 870
(1tr cotrJu..lio. e1lh r cotrdcnlor?0oo!F)
118h!r or any
CD
2000!8
I{IRING DIACB^I,I
FOR
RECTITTER.RECULATOR26' I7O
in conjunctior rlrh r brtt.ly

A
.hl.q\
Hft--
V
ITT,r\
@)
Y
CHANOING
THESTARTER
ROPE
(The nuobers stated in blasketa
Firlt ,enove EnaprinB (9), foop
Parl lock (6) antl the pawl (5).
Tools: Snap ring tongg
screrralriver
- 14 -
NEt'lTDSTARTER
PuIl starter grip out slouly untll reBlatance lB felt, then
pull out vlgorouEly but not fully up to the end. ABfa! a!
Polslble pull ln t,he direction the rope coEesout of the
abtave. By a rexind Epring the starter grip retuins to ltg
ori8inal poaLtion, Don't let the starter grip fly back.
Do not operatc thc engl.ne
if the reuind starter i8 defectLve.
a\
(@))
YI
refer to the ill.ustration )
6
0
oD
spring (8), circlip (7
),

. -15-
r Pull out the starter rope fully to the end, hoLd starter
housing (1) anil rope sheave
()) together in thelr porition,
There ls an opening Ln the rope Bbeave. The key clanp (q)
vl8Lble in the opening has to be pu8hedout in the oppoBlte i
aenaeof the pulting dlrectloD. PuIl the rope out of the
' rope aheave.
Tben insert the nex stapter rope into the rope aheave,
nount the key clalop ln the sane po8ition as it was before
and iernount tbe parts 5, 6, 7, 8 and 9.
Cautiont Do not renove EprLng container (2), this nlght
cause injurie8 l

DECARBONIZING
After approx. 50 houra of Use the cornbustl.onchenber should
ba de-carbonized,
lo do so: Eenoee cylLnder head. tlold cyll.ndera ln
place by suitable neane. UsLng
a acraper, the carbon scales
on the conbuation cha.nber of th€ cylinder head and on the
top of the piston ahould be renoved. Piston at top dead
center.
IIAIN TORQUINOSPECIFICATIONS
Cylinder head nuts I'18
Crankcase sererE l'16
rq8
l{agneto houaing nut (1.122
x 1t5).
Crankcaae
nuts (or -acreya) MlO
Exhauat manifold acre s M8
NB
18+24
8+10
18i24
80+90
]5+40
18+24
in.lb
150r 210
70+ 88
160r 210
?10
+ 800
t20 + 354
160* 210
"l

- 18 -
F.EULT-TRACIIICSCIIEDULE
Openthe fuel coc
k
Doe6gasoline reaeh
the carburetor? 1. 0asollne tank enpty
2. Blockage In tank cap
J. Blockage in fuel cock
{. Blockaae in fuel llnc
5. Needle valvc blocked
Doe6 gasoline reach
the en8ine? 1. Bl,ockage in carburetot:
Probablc fault
1. FLoat 6tuck
2. FLoat leakE
l. Neeille valve aloes
not
seat properl,y
Doesthe carburetor
keep flooding?
Has the engine becorne
xet with fueL? 1. Too ltuch use of atanter
2. Faulty ignition systen
J. Incotrect fuel nixture
Is there a spark at the
spark plug protector? 1. Poor contact between
ignition coil aDat
ignition
cab
1e
2. Ignition eable broken or
6hort- c
ircuiting
J. Faulty ignition coil
Is there a spark at
the spark plug? 1. El.eetrode gap too large
2. Bridging between electrodes
J. Insulator broken or uet
4. Spark plug oily
ChanBe the spark plug
16 the engine difficutt
to start? 1. Faul.ty ignition tining
2. Float needle doesnot seat
properly
J. Air cleaner bl.ocked
4. Fault in carburetor
5. Defective Epark plug

- 1Q -
1
a)
b)
c)
d)
e)
t)
c)
e)
f)
h)
t)
Englne "four-etroking'l
Air cleaner elenent dirgy
Needle jet worn
Jets too large
Too tnuch oil in
Faulty ignition
Exhaust port and
pipe blocked
Needle posit ion
the gasoline
timing
exhauag
too high
2. "spitting" in earburetor
a) FueI fifter blocked
b) Dirt in carbuPetor
c) Dirt in needle valve
d) Carburetor not Fecured
properly
Needle position too low
Faulty ignition tining
Spark plug loose or dirty
Incoryect elestrode gap
Incorrect caloric value
of spark plug
Ignition cabfe loose or
poorly insuLated
Piston rings stuck
Crankshaft oiL seaL yorn
Engine rrknocksn
Faulty ignition tining
Poor fuel supply
Heavy carbon deposits j.n
cylinder ports (glow
igniti ons
)
Pfay in gudgeon pin
Big-enal bea.ing or
cylindei bore worn
a)
b)
c)
DoeE the engine run
well at high r.p.n. ?
Does the engine run
t ell whenidLing? 1. Incorrect idle adj
us
tment
2, Faulty ignition timing
J, Faulty spark plug
q. Poor cyLinder sealing
yes
yes
Nov aLl
to York
traslng
Bhould be well,
ln a Eethodical
faults.
but reneEber
aequence when