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cristalclear13
Joined: 19 Sep 2007
Posts: 363
Location: Southeast Georgia
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 Posted: Sun Mar 08, 2009 5:45 pm Post subject: 503 Exhaust Gasket replacement |
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Have an exhaust leak and need to replace my exhaust gaskets on my 503. Looks like I need to order four of the part number 831-842. Any suggestions where to buy them from? (I'm in Georgia.)
I'll be taking the Rotax 2 stroke class in April with Aero Technical Institute to learn more about my engine, but want to tackle this job sooner since it's making quite the mess. From the picture in the CPS catalogue it looks like they just sit (two a piece) in between the engine and manifold. Anything else to consider?
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Cristal Waters
Kolb Mark II Twinstar Rotax 503 DCSI Sept 2007 - sold Sept 2012
Private Pilot Aug 2008
ELSA Repairman for N193Y April 2008
Rotax 2 stroke maintenance April 2009 |
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cicrn(at)telus.net
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| Posted: Sun Mar 08, 2009 7:11 pm Post subject: 503 Exhaust Gasket replacement |
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You will have to replace the gaskets but there is likely more to it.
Every Rotax 2-stroke I have had has warped the Y manifold after a few
hours of running. The fix is to plane the mating surface of the Y
pipe. My Rotax Service Centre rep told me to take the Y pipe off and
plane on a flat belt sander. Do it once and it should be good for the
life of the engine (manifold). It worked for me every time, no more
leaks. Another issue is when you have the cylinders off for any
reason, you need to make sure they true. The exhaust ports need to be
in plane (in line).
Regards,
Joe
On 8-Mar-09, at 7:45 PM, cristalclear13 wrote:
| Quote: |
<cristalclearwaters(at)gmail.com>
Have an exhaust leak and need to replace my exhaust gaskets on my
503. Looks like I need to order four of the part number 831-842.
Any suggestions where to buy them from? (I'm in Georgia.)
I'll be taking the Rotax 2 stroke class in April with Aero
Technical Institute to learn more about my engine, but want to
tackle this job sooner since it's making quite the mess. From the
picture in the CPS catalogue it looks like they just sit (two a
piece) in between the engine and manifold. Anything else to consider?
--------
Cristal Waters
Kolb Mark II Twinstar
Rotax 503 DCSI
Read this topic online here:
http://forums.matronics.com/viewtopic.php?p 33812#233812
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cristalclear13
Joined: 19 Sep 2007
Posts: 363
Location: Southeast Georgia
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| Posted: Wed Mar 18, 2009 5:48 am Post subject: Re: 503 Exhaust Gasket replacement |
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| cicrn(at)telus.net wrote: | You will have to replace the gaskets but there is likely more to it.
Every Rotax 2-stroke I have had has warped the Y manifold after a few
hours of running. The fix is to plane the mating surface of the Y
pipe. My Rotax Service Centre rep told me to take the Y pipe off and
plane on a flat belt sander. Do it once and it should be good for the
life of the engine (manifold). It worked for me every time, no more
leaks. Another issue is when you have the cylinders off for any
reason, you need to make sure they true. The exhaust ports need to be
in plane (in line).
Regards,
Joe
|
Joe,
Looks like you might have something there. I replaced the outside gaskets and flew her, and there was still some leaking on the front exhaust port. I may also have to take the cooling shroud off and replace the inside gaskets (thanks to Gerry Olenik for letting me know where the second gasket went since it wasn't in the diagram).
Replacing the outside gaskets ended up not being as easy a job as I thought it would. Two of the bolts wouldn't start so we tapped the holes and died the bolts, then it went much smoother.
When I flew, my takeoff RPM was only going up to 6000 when it normally goes up to 6200. I don't see how anything we did could be related to that though?
| | - The Matronics RotaxEngines-List Email Forum - | | | Use the List Feature Navigator to browse the many List utilities available such as the Email Subscriptions page, Archive Search & Download, 7-Day Browse, Chat, FAQ, Photoshare, and much more:
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_________________
Cristal Waters
Kolb Mark II Twinstar Rotax 503 DCSI Sept 2007 - sold Sept 2012
Private Pilot Aug 2008
ELSA Repairman for N193Y April 2008
Rotax 2 stroke maintenance April 2009 |
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cristalclear13
Joined: 19 Sep 2007
Posts: 363
Location: Southeast Georgia
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| Posted: Wed Mar 18, 2009 5:51 am Post subject: Re: 503 Exhaust Gasket replacement |
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| cristalclear13 wrote: |
I may also have to take the cooling shroud off and replace the inside gaskets (thanks to Gerry Olenik for letting me know where the second gasket went since it wasn't in the diagram).
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Correction to that...thanks to John Hauck for letting me know where the second gasket went. Gerry told me I could try replacing the outside gaskets first.
| | - The Matronics RotaxEngines-List Email Forum - | | | Use the List Feature Navigator to browse the many List utilities available such as the Email Subscriptions page, Archive Search & Download, 7-Day Browse, Chat, FAQ, Photoshare, and much more:
http://www.matronics.com/Navigator?RotaxEngines-List |
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_________________
Cristal Waters
Kolb Mark II Twinstar Rotax 503 DCSI Sept 2007 - sold Sept 2012
Private Pilot Aug 2008
ELSA Repairman for N193Y April 2008
Rotax 2 stroke maintenance April 2009 |
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lucien
Joined: 03 Jun 2007
Posts: 721
Location: santa fe, NM
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| Posted: Wed Mar 18, 2009 6:19 am Post subject: Re: 503 Exhaust Gasket replacement |
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| cristalclear13 wrote: | | cristalclear13 wrote: |
I may also have to take the cooling shroud off and replace the inside gaskets (thanks to Gerry Olenik for letting me know where the second gasket went since it wasn't in the diagram).
|
Correction to that...thanks to John Hauck for letting me know where the second gasket went. Gerry told me I could try replacing the outside gaskets first. |
The leaking exhaust at gasket syndrome, if replacing the gaskets and torquing the bolts correctly (195 in/lbs when cold) doesn't cure it, is usually caused by the poor support of the muffler and/or way too strong springs holding the tubing together.
The muffler mount has to support the can so that the manifold and elbows don't take the weight of it. Also, the springs used on the elbows have to be loose enough to allow the elbows to flex a bit, isolating the rest of the muffler from the manifold.
What sometimes happens otherwise is the manifold manages to rock ever so slightly under the vibration of the motor, deforming the gaskets or worse, causing the black stuff to still leak even when the bolts are torqued down.
Replacing all the gaskets outside and in and torquing the bolts will usually fix it if no warpage anywhere has occurred. The exhaust manifold bolts should be checked frequently with a torque wrench at first (i..e on a cold motor before every flight for the first 5 or 10 hours or so) as the gaskets settle in.
LS
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LS
Titan II SS |
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