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TRANSCRIPT
ROTAX.
P A R T S L I S T NO. so+
F O R N O T A X E N G I N E
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ORIGINALTEIL
GENUII{E PART
564
Table of conteniE
CrankErtaft' Baldcer Dlive, Cylinder, Etectric Sta!te!
1J Transnission
7 7
25
t7
19
4 1
29
1 I
t1 can shaft Drive
15 Ienition Unit
ctutch, Kick start
clutch cove!, Eleciric sbaltet
cyllnder Head, cd Stlaft, valve coler
Tinlng Belt tloEins, einins Belt cove!
valves, Rocke! ArN, Adjustrent sclet
Efectric start.. Palts
va lve, o i l ! i1Ler E lenent t Tani t ion cov6!
Repai! Tools, Gasket Set
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I G N r T r O N C O l r A s S Y . . , . . , . . . . . . . . . . . . . . . , ,
P R O T E C T T O N C r p . . . . . . . .
! 4 I E L D E D S o A q < P L U 6 0 R O T F C r 0 C . . . . . . . . . . . .
s P A R K P L U G t ? N G ( 0 3 E A . . . . . . . . . . . . . . . . . . .
^ i r o L l r I E i - 8 o t . . . . . . . . .
L O C T T T E 2 Z i V t 0 L E T 1 0 C C . S E C U R . . . . . . . . , .
s r L A s r l c 7 3 ?
1
3
1
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6@5 E , A
@ e { '
E L E C T R I C s T A R T E P P A R l S
1
2
3
1 0
t l
1 3
r t
1 9
2 0
2 5 0 1 3 0
232 260
2 1 0 5 3 0
2 4 1 1 3 0
3 t 0 5 1 0
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Y A L V E ' ' I L F I L T E P E L E ' l E N I I
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212 620
2 1 2 5 1 '
2 5 1 3 3 0
t
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P R E 9 S I q F q C - A I N I \ L
c U I D F p r N . . . . . . . . . . . . .
5 P R I N C . . . . . . . . . . . . . . . .
c r J r D - o r N s c r e ! . . . . . . .
o I | c I | r L c c o v E q . . . . . .
P L J C S C q . l l 1 / 3 - 2 7 \ d r . .
o - p , N c 6 0 - 2 , 5 . . . . . . . . .
L Y L , s ( q E k r 6 ( 2 0 . . . . . . .
I P I G G L O C O I I
T ^ P T l t C ! C R F k
r A P T r r E - S C R a r n 4 X 3 . . . . . . . . . . . . . . . . . . . . . . .
o u B s E q o t J c . . , . . . . . . . .
r c N l r I o N c 0 v F R . . , . . . . .
a a B r r r o r 0 E A t M F ! . . . . . . , . . . . . . . . . . . . . . .
D 0 k F L 9 , 3 r 1 0 , . , . . , . . . .
c Y L . S c R r H n 6 X 3 0 . . . . . .
c A E L F H 0 L D F C , 0 U I t F . . . . . . . . , . . . . . . . . . . . . .
. Y L . S C o F H a 6 X 2 5 . . . . . , .
p L U C S C R E N r ! 1 3 X 1 , t . . . .
c F , r r r c 0 v F 0 . , . . . . . . . . .
. t . . c o k f l o t 2 5 . . . . . . .
L C C I r r 2 : 1 v l 0 L t - l 0 c ( .
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2
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1Z o , \ E P S r r 0 L r t r . . . . . . .
2 7 6 3 2 2
2 7 6 3 t O
c u r D E s 1 F E v E . . . . . . . . . .F O q O I L 5 E A ! ' O I L P U N P S I ] A F T
S P A R K P L I J G I { R E N C H 1 3 . . . . . . . .
V , {L VE CLEARANCE F€ELER CACE
D ! C O X P R E S S I O N S H A F I
F 0 R K T R E N C H 1 1 X 1 1 . . . . . . . . . . . . . . . . . . . . . . . .
1 0 / 1 1 x n . . . . . . . . . . . . . .
G R t P F 0 R S C R E H 0 R M R . . . . . . . . . . . . . . , . . . , .
S C R E H - D R I V E R S A L D E - F 1 A I . . . . . . . . . . . . . . . . . .
N R € N C N 1 1 M f l . . . . . . . . . . .
T N S E R T T O X J l 6 ! S S Y . . . . , . . , . . . . . . . . . . . . . . . 1F O R O t L S E A L 3 5 0 0 5 5 ' C R A N K S H T F T I l A C N E T O S I D E
I N S E R ' I O X J I G. O R O I L S € A L 2 ] O 3 9 5 ' N A I N S H A F T
I N S E R T I O N J I 6F O R O I L S E A L 9 3 0 7 1 9 ' C R A N K s H A F T C T I J T C H S I D E
T N S E R t I O N J I G A S S Y . . . . . r . . . . . ! . . . t . . . . . . .F O R O I L S E A L 3 ] 1 2 6 0 ' K I C K S T A R T S H A F I
l N 5 E R r l O N J r C . . . . . . . . .F 0 R 0 I L S E A L 2 3 0 6 9 0 '
I N S E A T T O N J r 6 . . . . . . . , ,F 0 R C r L S E A L 2 3 0 3 ? 0 ,
r N s E R l l O N J I C . . . . . . . . .F O R O I L s E A L 3 5 0 0 5 5 '
2 5
2 7
3 2 2 7 6 5 3 5
277 470
p l t T r \ c r N c s p l N \ l ' . . . . . . . . . . . . . . . . . . . . . .T O I I O U N I P I S T O N I N C Y L I N O E R
P r J L L F o d S S Y . . . . . . . . , . ,F O R T I N I N G P U L L € Y
' J L L r o d s s Y r / | 5 ^ ' ' 5 . . r . . . . . . ' . . . . ' . . . . . .
p U L L E R p L r r E A S S Y . . . . . . . . . . . , . . . . . . . . . . . .C R A N ( C A 5 E D I s A S S E ' l B L Y
I t L A S T r C / t 2
e o L Y ( o T F c \ 1 0 0 c , , ( L I D F
p u r L E R a s 5 Y . . . . . . . . , . .
c y ! . s c R E r _ x 3 x 4 0 . . . . . . . . . . . . . ' . . . . . . . ' . . . 2
p l r L L € R a s s Y . . . . . . . . . , . t
T R E S T L E A S S Y . . . . . . . . . .
P U L T E R P L A T E A S S Y . . . . . . . . . . . . . . . . . . . . . . . . lCRANKSf iAF I D ISASSEXBLY
. . , . . . . . . . . . . . . . . . . 1
P U L L € R R I X G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B0L- r t 2x250 FOR PU! rER R I r {G . . . . . . . . . . . . . .
P U ! t - t N S P T N o L E f l 1 3 X 1 " A S S Y . . . . . . . . . . . ' . l
c r r r T c n H ! a l o c K I N G T o o r 4 S S Y . . . . . . . . . . . . . l
L 0 I A T I N C s O L T i l 3 X 3 0 . . . . . . . . . . . . . . . . . . . . . . I
v r L v € s P R I N G t P U S H r N S t R T . . . . . . . . . . . . ' . . .
R $ 1 6 X R E n C I ' | 1 j / t 5 , . . . . . . . . . . . , . . . . . . . . . . . ' � |FOR CYLINOEi HF. ID I IUT
P U L L E R A S s Y . , , , . . . . . . . . . . . . . . . . . . . . . . . . . . 1FOR 6 : I i INGS' CLUTCH SNAFT AND sATANCER SHAFT
E X T R A C T O R S 1 E E V E . . . . . . . . . . . . . ' . . . . . . . . ' . . 1
P U L L E R A 5 5 V . . . . . . . . . . .FOR BALANC:-R GEAR
I
2
I L [ . X O . P A R T N O .
t 1
L O C T T T F 5 7 4 0 R A ] { G F 5 0 C C . S E l L r n 6 . ' . . . . . . .
r 0 c t I T € 2 2 1 V I O L € l r 0 c c . s E c u n . . ' . . . ' . . .
! o c T t T E 6 4 a 6 R E E N 6 C C . S E C l l R I t l c . . . . . . . . .
r - o c T r T E A I T r - S : I l e 1 0 G . . . . . . . . . . . . . . . . ' .
c A S r ( E T S E T . , . . . . . . . . .
1
1
1
1
BOIVBARDIER-ROTAX GI\,1BHMOTOBENFABRK
,\-4623GUNSKIBCHEN AUSTRIA tffil\?.J
T E C H N I
ROTAX EN6INE TTPE
S i n 9 l e c y r j n d e f 4 s t r o k e n o t o f c y c l € e n s i . e ,a r f c o o l e d , s l n g l e o v e f h e a d . a m s h a f r ,t l f t i n e b e l t d r i v e , f i t h i n t e g r a r e d 5 s p € € d
r l r h h a t a n c e . h a f t
l r - q h t a l l o y c v l i n d € r e l t h c a s t i . o n 5 t e e v e
l i s h t n e t B t , s o t i d s k i . t , c a s t
l c o n o r e s e i o n r r n q ( c h . o m e p t a t e d l
1 o i l s t r a i n € r . 1 n s a s s y .
m o n o b l o c k d e s i s n , 4 v d l v e s , f o f k e d l n t e tD o r t , z s . p a . 6 t e e r h a u s t p o . t s
t r n l n s b e l t , b r e a k - p . o o l d e s i s n , c e n s h a f to n b s l l b c s r r . s ' o ! r c r d r t r s , t h r o t l e r 5
0 , 0 5 m m , i n t a k e a n d e x h a l s t
ou t le t 225 desrees- ln Ie t 240 desrees
D b . 3 6 1 E
D r : b l d c e n e r t , . c
C o n o r e s s r o n . a t i o
V E l v e s a p l c o l d e n s i n e l
1 ^ l e t c l o s e s 5 r , d e g r e e s A B 0 C
3 6 , 5 d e e r e e 5 A B D co ! t l e t c l o s e s 3 , 5 d . - r r e e 5 A T D C
c a p a c i t o r d r s c h a r s e i s n i t i o n , f ! l l y* t t h t l n i n e a d v a n c e
t ! 1 1 I o a d 2 9 d e s r e e s E T 0 C a t 7 0 0 0 r p r. ' , q . ' o n 0 0 0 -
s 0 4 r r L - 8 5
E n q i n € l u b . i c a t i o n r d r y 5 ! m ! L u b r i c a t i o n , o i l H D 3 0 U 5 0
T . a n s m l s s l o n I u b r i c a t s p l a . h l ! b r i c a t i o n
f l y * h e e l s e n e . E t o r 1 2 V t g 0 \ 4
Reg! la r saso l lne RoN 91 -
d o u b l € t r o c h o l d p l n p
m u l t l - F l a t e c l u t c h i n o t l b d t h
s t fa i lh t too th spur sear ins 32 /76 - 2 ,375
T . a n s n i s s l o n : l n t e g r a t e d s - s p e e d t r 6 n s m i s s l o n , c o n s t d n t
T r a n 5 n i s s i o n r a t i o s i p f i n r 3 2 / 7 6 = 2 , 3 7 5
1st speed = 32 /1 ,1 , = 2 ,9892nd sDeed = 24 /12 = 2 ,O3 r d s D e e d = 2 I / I 5 = ! , 44 t h s p e e d = 1 9 / 1 7 = 1 , 1 1 4s t h s p e e d = 2 l / 2 3 = 8 , 9 1 3
t o t a l r a t i o t i p r i n x i s p e e d ll s t s p e e d 6 , 9 0 92 n d s p e e d : 4 , 7 53 r d e p e e d r 3 , 3 2 s4 t h s p e e d : 2 , 6 5 45 t h s p e e d : 2 , 1 6 4
other ra t ios op t iona l
sprocket : 17 1 .e16, 5 /a t \ /4
6 € a r 3 h l f t i n g : l e f t h a n d s h l f t l n s , n e u t r a l b e t w e e nl€ t and 2nd sedr
k i c k - s t e r t e f , o p t i o n a l e l e c t r i c s t a . t e r
2 8 H P . t a p F . o t 6 0 0 0 r r m
36 Nm at 5000 rFm
m.x recomnended roh 7500 rDn
a F p r o x 4 3 k e l r l t h e l e c t r i c s t d r t e r 4 6 k s l
, a . ! e r l t h o ! t o t i ! e
BOIVBARDIER.ROTAX GIVBH
A4C23 GUNSI(RCI]EN_AUSTN]Arddoo: .4+0)7a.rr o.rdda! 4 {0)726 t0
ROTAX 4-STROXE ENOINES
CENERAL
Single cyflnde!- motorcy c le-englne , ait_coo1ed,
wi ib ln tee la ied 5-sPeed gea!_bo*
dry sap lublicailon
single ovelhead cdshaft, 4 vahe3, loof6haDed
csshaf t d . ive wl th toothbel t ,
C,D. ign i t ioD unl t , e lect ron ic , {1 th au io@t ic
aalvance, with l-pha.e genelatot 12V 190t,
can be .upplied vith o! withoqt balance ahart'
3Ee-:lg .3Jre-r.gl rype rub rype )bu
8 97 9 , 4491r
7 0 ' 5
Disp lacehent c , c .
7 9 , 5
t49
9 , 6
7 9 , 4
9 , 2
8 98 15 0 4
948 1562
9 , 6
Valvet iming 2 ' ,
4.?ave rool shdoe @Tburrol chdroer wilh 'Pnra sozrl pug the @nbu\lion cfddbF' s
"or " io "u" " , 'o r r t r t rn " " -q ' " " !ssaaqa ' l s lov" revo lu l ioF 'dnooe l b rFd{10ra ' 'ep ' lo t r 'am
shalt237 675,237 460 and 237 e65) Rollervalve rocke6
Ln et valle: 2\a34 (2 x O 36loreng ne rype 560 and 604)
Out le lva lve 2xO30
valv€aaowilh..d enoi^e: out€t and inlel0 05 nm
34SG9
1i- , fs$d' n Lf Nw 237 667
sloaesolsllla
opens 42,5 oBBDC2,5 0 ATDC
stroke 5,32 (7,9 valve stroke)
sroke 5,€5 (7.9 valve srroke)
ope.s 36,5 oBBDCcross 8,5 0 ATOCstoke 5,82 (7,9 valv€ strcke)
opens 36,5oBBDCcloses a,soATDCstrcke 5,82 (7.37 valve stmke)
sloke 4,32 (6,51 valve strcke)
opec 60,5 oBBDCdoss 20,5 oATDCslrcke 6,57 (8,9 valve strcke)
2,5 0BTOC
508
SonEnduo
506 GS/504 MX/560
so{ElallraclNW 237 675
506 - s60NW 237 800
564
504 - 560 FTNW237660
56A,-0!4,GS?MCNW237465
3 O BTDC
5,35 (7,9 valve si.oke)
5,82 (7,s valve slroke)
4 O BTDC
s,77 (7,8 valve stroke)
5 O BTDC
4,08 (5,5 valve stbke)
67,50ABOC6,57 (8,9 v€lve slroke)
opens 74,5oBBDCcloses 30,50ATDCstoke 7,06 (9,56 valv€ stoke)
srok€ 6,37 (9,3 valve stroke)
,15,5 o BTDC71,50ABDC
12081DC
54OBBDC 12 O BTDC
7,12 (9,64 valve strcke)
,14 O BTDC
7,79 {10,5s valve sroke)
20 O BTDC
7,14 (9,67 valve stroke)
stokeT 79 (10,55 valve strcke)
stoke 7,14 (9,67 valve stoke)
- t -
Lub!!cation
The engine is desiened for drv sap lubrfcation'
The oil is circulated bv a double tlochoid lup (ple3sure
5nd scavengina pwp). h the nai! cilcuit alter the p@p
there ls a pape. oi1_tille! vith intesrated btpass-talve
wbich opens {hen the fltte! is blocked. ror tine clealtDe
there is a celtlifusel separator in the cfankshaft'
The pape! filte. is accessible bv unscleeing the oil filte!
,hich is in the Bagnelo side clankcase ha1f'
P@p capaci iv . app!o* . 5 r i t les /min at h ' 8000 1/n in
o i l o lesBure
at eam eraine (drv 6un! ier!€ratule aPplox. SOoc) 0,5 ba!
ple.sure at nM = 5ooo 1/nin, neasuted at the conne'tine nipple
N P T r / 8 ' o n b n e o i l f i l l e ! c o v e r -
Oil qualitv
castrol Ofx2 15trl50 HD o. sinila! hiBh qualitv bland o11'
.- oi1 to be cbaneed eeelv 2.500 k!
olt fifter to be changed eve.v 2.500 lon
cfeaning ol the celtlitueal sepalato! in tlre clankshaft at
evely enslne levision.
- ! -
ip.in = 76 / t2 = 2'175
1st speed t2 / 77 = 2 '909
2nd .Peed 2\ / 12 - 2 'o
l ld s !€ed 27 / 15 ' r '4- 4 th 6peed 79 / 77 = I ' t t l
5 th 6peed 27 / 2) " 0 '971
to la l sea! ra t los = rpr in . .gear
1st 6 ,909
2nd \ '7 ,
l ld 3 ,325r t th z ,n) t
5 ih 2 ,768
- 5 -
Vorschlog fur Auspuffsystem Rotox 348/506SUCCESIION FON IXIIAIJST SYSTEN
roa RoTAx-4-sTRoxE ENGTNES 148 / 506
,.f'1
s.hotd'inPk. na4rh!ext raust s i leDc€! o fg leatest poss ib le vo lae
Zylinderkopfasputlsqjgb-
Skz. 270'
d
sucoEsrroNs roR EISII!,INI]TALLAII0NIN !!!-3!3.4E
Fo! .oo t lng leason6 and becau6e o f the 'educed space lequ i re -
nent the na in tubes o t the f .ame shou ld be used as o i l tank '
Nben nak ing the f rade, care bas to be taken
fu l l y a l l se ld ing d lops , res idues o t cor ros ion pro tec t ion o i l
and meta l ch ips f ron the iubeE.
schener see drae ina , append ix no 1
The o i l L ine lead ing to the pressure p@p is connected on
top ot the cfuich side ciankcaEe haLt end usually gets connec_
ted rith the oil ialk in the trde bv a nipple and a tube
ins ta l led be tween the t in ine be l t l rous ing and the c t t inder
To avo id tha t fo re ien na ter ia l danages the o i r pup ' a ne ta l l i c
f i l te r e le ren t has to be p laced ln tbe f rane ou t le t ' Th is
f i l te i shou ld be d ime ls ioned so tha t su f f i c ien t f los ts guaran-
tee i l a lso in { in le r .
The oil leturn LiDe fron the scaveneing punp is connected ai
the nagneto 6ide clankca6e halt rt is useful to connecl rhe
l lex ib le o i l tube to a s tee l tube f i *ed on the f rane ' Th is
oil tin€ should be a!!a!sed in the oit tank 5o tbat the oll
ou t le t 16 above the o i l Leve l and the o i l le tu ln t lo { can be
seen th lough the o i l l i l l e ! socket in o rder to chec l the
The o i r ta ik i5 vented th rough a tube connected to tbe eng ine
(n ipp le on va lve cover ) to p revent o i1 loss in case o f b 'ak ins
or i l the motor .Yc fe la11s do tn .
- T -
The c rankcase (and the o
tank) a re then ve l ted th rougb the
b ig vent open ing a t the rear o f the c lankcase v ia an o i1
separa tor box in to the carbure io r .
The oi1 separato! box is preferrablv f,ounted at the front
E ide o f the a i rbo t and shou ld no t have anv sna} l 6ec t ion
areas (be igb t H n in . 20 m) . separa ted o i l shou ld be ab le
to lLok back f ree fy in to the eng ine .
The execut ion o l the a i rbox depends on lbe no ise requ i renent6 '
The n in inm s ize sbou ld be I 1 i i .es .
o i l tank capac i tJ
vben dec id ing on the d inens ion ! o f the o i l svs teor the fo t lo_
l ing fac ts have to be taken in to cons id€ ta t ion :
- About 1 l i t re o i l iE accumula ied in the drv s$p a t h igh
r .p .n . , in par t i cu la r {hen d t iv inA the no torcvc le uph i1 l .
- o i l consspt ion (d i r fe rence be t reen n in inum and f tax inu o i l
leve l ) i6 1 l i t re ( i i te rvar o r o iL leve l inspec t ion eve lv
- p lus a n in inum o l 1 l i t re o l d isposab le o i l quant i t v in the
o i l tankr lhere the o i1 tank in the t rde har to be d tnen-
sioned so that the renaining oi1 quantitv of l litle gualan-
tees ihe o i l c i rcu la t ion a t a l l poss ib le inc l ined pos i t ions
o! the no torcyc le (uph i1 l - do{nh i l l ) . ( I f th is i6 no i the
case, tbe o i l quant i t y has io be inc rea6ed un t i t the o i l
sup l l y fo ! the ens i le i s su f f i c ien t lv suaranteed. )
- s ives I l i t res n in inun capac i tY
- 8 -
The o i1 leve l in the tank shduld be checkeal and adjusted
Run the engine un i i l wam, at ter some n inutes of id fe a t
s tandst i l l o t the noto lcvc le re l i l l o i l u ! io the nax inun
mark at tbe o i l d ipst ick o ! inspect ion g lasE.
vent i la t ion of ihe lubr icat ina svsten
Necessary af te t the f i rs t ins ta l ]a t ion of the engine o!
af ter d lsconnect inC of the o i l punp Euct ion tube f lon the
engine {n ipp le at c lu tch-s ide crankca€e hal f ) .
1 . Connect o i l tube to enc ine and o i l iank.
2. ! i11 ap! ro* . 1 ,5 1 i t les of o i1 in to the o i I tank.
f . unscre{ o i l f i f te ! cover on nasneto s ide ( . isht ) crankcase
hal f ( l in t . hex. sc le ts M6) and lemove o i1 f i t ter .
4 . Renove presEule va lve s i tuated in the o i l l i l te r hous: ine
r i th a screwdr iver togeiher wi th the rubber p lug
5. PulL decompless ion leve! and crank the enaine * l th the k ick
sta l t lever unt i l o i1 comes out o t the ho le of the l lessure
6, Reassemble the l lessune va lve .onplete, the o i l f i l ter and
the cove! k i th lhe seal ing r ing.
( & N f i l te ! w i tn toan pre-separa to ! o t a s in i la r t i l ce r .
- 9 -
Startlng the enaine
It is considelably ea.ier to start the engile if the dran\-
shaft is In the correct position befole operating the kick_
The deconpress ion levea lac i l i ta tes the pos i t ion ina o f the
crankshaft to staat position ad the sta.tina of the engine
by pushing the notorcycle.
lhere is a rindow in tbe ttnine dlive cove! and a colour nark
at the cdshaft to indicate the staltirs po.ition.
staltine procedule
- Clank the e.sine ihroueh tith the kick stalt leve! until
the colour @!L can be see. in the xindow. For this the
deconpres6o!
- Release th€ decohglesso!, bline the kick start lever back
in to the h lehes t pos i t ion ( re tu lns by spr ins fo rce) .
- Sta!! the engine by a vtgorcus klck. To stari a cold engine
i t i s necessa ly to ac tua te the choke.
I append ices
-!
;
!
iI
/i
71
I
il-r:i r i r l i :
lrrllfil1ltu.aat:):
l
Nippohdenso ien i r ion un i t
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