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
NEdition: 11 1988
t
JffiT
ffi BOIvIBARDIER-ROTAX
GMBH
VOTOREI{FAARIK
A-4623
Gunskichen
- Auslria
rnleron
{O/246'
.rfl.9',rcler
?55dGb'okd
Ielesranmadresse:
Bonrbrota
x Gunski.chen
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:ollu1an(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 notice.
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-INPROCEDURE
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 sec sec nl n rnin min
1
155
5)
5
5
10 20 l0 lro 50 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
sition.
i6, aayEmetrical, therefore, at assedbly
oLsc on gear to determine best
CA
NBURNTOR
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
excessive airst re
an.
l,lote
:

-5-
qf!G-Clrburetor
IJ -----1 |
44
5
4
1.rl1
'"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 tlrcre is
the ignition cables
checked,
ICNITION UNIT
The RoTAX cngine is equipped with a BOSCH
maEnetogeneralor
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]<ercontacts 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'ITOF 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.
POLESHOEGAP
t{hen correcL timing is achieved, check pole shoe break-away
gap. The gap must be within 13-17 mmot .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
)'<
oqardboard
strip
nagnet

Tining adjusgmenoand repair of iEnition unit6 6hould hest
be left to a skilled Jnechanic, lnproper handlinE can easily
cause none troublea Hith such delicate parts.
IIIRINC DIAGRAM
Particular care
cable6 (J) and
to the i8ni t ion
has to be taken
the rDaEsc ables
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
connect
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
essary
bours of opera-
a) to clean the spark plugs every approx. 10
tion or to replace thern.
b) An i8nition danpingbox, 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 .beng spark on
If there is still a spark,
T
I
P.t.o.
side
ignition
coiI
darnping
box nith reversed polarity.
both pluqs Hhen cranking the engine.
the dampingbox 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_p99c!qlc!
1) Danping
box defect or reverse connected (see a))
2;) Fcrle-ring l)reak-awaygap out of tolerance (defecti.ve
;loodrtrff-key or lrrong armature plaie adjuEtnent
(
see page B)
damping
box 8655Zz
j.f there is now a sparli,

- 11 -
LICIITI]IGCIRCUIT
The BOSCiI magneto 6enerator produces, apart fron the electric
current required for the ignition, 12V 1ll0Walternati-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. ninimunrcontinuous 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
FONELECTRIC
STARTER
fus? 151
electric-sta!ter

},IRINGDIAGNA
(not 1im!ted to FONRECTTFIER-FECULATOR
25It 870
minioun of 1 Ampere
consumption)
IInINC DIlclnl FOllIIECIIFIEn-.caolaror 25! 8tO
ln r clrcult vlthoor b{tr.ry
! (< I
-l-' ..r1!11v.oaruo.r'!
tIlIltC DIiCnl8 FOnRECTIFIEn-..guletor 26! 870
(ln conlun.tlon !1th a eondcn3or2000 uF)
20OO
!F
IiIRINGDIAGRA'{FORRECTIFIER-REGULATOR261 870
in cotrjurction vith r b.ttert
CD
CD
-T-
I
3

- 14 -
T.IINDSTARTEN
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 SfARTERROPE
('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,
rDountthe key clamp in the same position as it was before
and remount the parbs 5, 6, 7, I and 9.
cautionl Do not rernovespring 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: Renrovecyllnder heaal. HoId cylinclere in
place by suitable rneans.Ueing a scraper, the carbon scales
on the co,nbustionchamber
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,la8netohousing
nut, (1122 x 1,5)
Crankcasenuts (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
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 carburetor?
1. Blockage in carbure
tor
Does gasoline reach
Probable tault
1. Floab stuck
2. Float leaks
J. NeedLevalve 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