BOMBARDIER ROTAX 532 User manual
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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
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