Rudi’s 503 Teardown and Inspection with Photos

[Smiley]

Hello Rudi

Maybe it will be a good thing to replace both pistons, atleast then you will know both piston sets are new. Just scared the piston in good nick "now", can start to give troubles in lets say 200 hours....?

Your thoughts??

[RudiGreyling]

Hi Riaan,

I thought about that, but after measuring up the 'good' piston after 435 hours and it is still within .03 mm of a new piston it is not worth it. The same one is going back until next inspection in 150 Hours.

Regards
Rudi

[Smiley]

Hi Riaan,

I thought about that, but after measuring up the 'good' piston after 435 hours and it is still within .03 mm of a new piston it is not worth it. The same one is going back until next inspection in 150 Hours.

Regards
Rudi

[RudiGreyling]

<SNIP>...if you could take a picture of the head for me, <SNIP> I need to be able to see is the depth and shape of the groves on the sealing surface on the head cannot quite see it in your pics, so a good close up would be fantastic <SNIP>.

Nick, I'll see what I can do for you in the next day or so. Rudi

Here you go I hope it is what you're after..

[RudiGreyling]

I updated Part 2 with more pictures, and will soon add some info in part 3.

Nobody come forth yet with a SOFTcopy (.pdf) of the REPAIR manual, can someone please assist ???

Regards
Rudi

[Morph]

Rudi,

you can get everything here http://www.ultralightnews.ca/rotax503/index.html

[RudiGreyling]

Rudi,

you can get everything here http://www.ultralightnews.ca/rotax503/index.html

Hi morph, thanks, a lot of good info there, but I am after this manual "Repair Manual" in soft copy??? The site also do not keep it.

Rudi

[RudiGreyling]

Hi Guys,

I updated Part 3 on the first page wiht the re-assembly...

I still like someone to post the links to the repair manual, or email it to me if you have a softcopy, I'll host it. You really need it if attempting to strip these little motors as a backup reference.

I hope a couple of people found this topic usefull.

Kind Regards
Rudi

[Duck Rogers]

Very very nice Peter!

That's excellent reference material for anyone wanting to do up the 503 motor. Well done Rudi!

Duck Rogers

[wamatt]

Really enjoyed reading that, thanks!

[nickjaxe]

Many thanks rudi for the close up shots of the clyd head that will be a big help to me.

Nick.

[RudiGreyling]

Just an update,

On Saturday I managed to mount the engine back on the trike.
Primed her as ussual, mags on, flick the prop and she started on first flick.
I ran her in as per rotax run in procedure and she is purring like a kitten.
Have done 2 subsequent test flight of 1 hour each above the airfield 2000 ft AGL.

No teething problems so far!

Just a couple of more test flight runs over the airfield then I am ready to join the guys for outings again.

Regards
Rudi

[Smiley]

Welcome back, it was getting very lonely in the air all on my lonesome ownsome.....!! :D :D

[RudiGreyling]

Welcome back, it was getting very lonely in the air all on my lonesome ownsome.....!! :D :D

Yip C U on Friday it is a long weekend, so we fly fly fly...!

[alan]

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