Rudi’s 503 Teardown and Inspection with Photos

[RudiGreyling]

Hi Rudi

Thanks for all the excellent info. I have just been through the same process except I had someone do it for me. I did not know at the time what to do and I had also been looking for a repair manual to no avail. The long and short of it was that I had two new cylinders, pistons, rings, overhauled carbs, new flyingwires ect and the final result was an account of R 15 500. If I had nkown this I might have just replaced the engine with the trade in option.
If you find a PDF copy of the repair maunual please could you share it.
Thanks
Alan

Hi Alan,

No I still haven't found a softcopy of the repair manual...hmm I think rotax does it on purpose to protect the authorised guys...

My account was +/ R5 500, with everything inspected, measured, tested and components replaced that was necesary and did not meet the wear limits, everything documented in the log book. Carb and Fuel pump was also overhauled. So the engine had a Mayor Overhaul Done, and now it is a Zero Hour SMOH engine for a third of the rebuild price.

Regards
Rudi

[RudiGreyling]

OK I have searched high and low and cannot find a softcopy. I got a new hard copy recently and scanned it for you guys before it gets abused in the workshop. I converted it to PDF for you guys, just don't tell Rotax. (silly that they don't make this one available in softcopy)



http://www.rudigreyling.com/pictures/ro ... al_503.pdf

Regards
Rudi

[nickjaxe]

Many thanks Rudi very interesting.

Nick.

[alan]

Rudi

Thanks again for the DVD and the manual :D Although the DVD is very nice to watch my wife gets a bit awkward with me when I work on my engine on the lounge floor. With the hard copy I can now take it out to the garage.

[DieselFan]

Is it necessary to re dyno these engines after a rebuild?

Also some additional pdfs http://www.rotax-owner.com

[Mogas]

TOP JOB Rudi!
Very nice to see this done properly and shared as well. Although I am not currently running a 2 stroke I have archived all this for future reference. Thank you. Aside from that, I am not able to view your jpegs on the forum (viewed them on your site). Any tips anybody?

[RudiGreyling]

HI Diesel, I did not Re-Dyno mine, first time I am hearing of it. Mine is still running sweeeet after the rebuild, got about 75 Hours on it since rebuild.

HI Mogas, I fixed the pictures, it should show now, I changed Internet Host last year but did not update this thread. Try now...

Regards
Rudi

[Mogas]

Pictures sorted! Thanks
Also thanks and well done again, this time for the carb/pump teardown thread.

[RudiGreyling]

BUMP...just to ensure it does not get lost in the post archives.

[Massimo]

Well nice work Rudi. I didnt see your tear down until you bumped it. Hey when i need to do my engine you welcome to assist.

Good to know that everything is checked and clear for another couple of hundred hours.

[grostek]

Hi Rudi,

Thank you for posting the complete overhaul and also for the 503 manual.

Kind regards,

Gunter Rostek

[falconp1]

Just to refresh this post by Rudi

[Jean Crous]

Thanks Rudi, now who is going to do up a Rotax 582, or a 618 ?
Jean