Today's Message Index:
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1. 06:49 AM - Re: 503 Exhaust Gasket replacement (cristalclear13)
2. 06:51 AM - Re: 503 Exhaust Gasket replacement (cristalclear13)
3. 07:20 AM - Re: 503 Exhaust Gasket replacement (lucien)
Message 1
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| Subject: | Re: 503 Exhaust Gasket replacement |
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?
--------
Cristal Waters
Kolb Mark II Twinstar
Rotax 503 DCSI
Read this topic online here:
http://forums.matronics.com/viewtopic.php?p=235082#235082
Message 2
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| Subject: | Re: 503 Exhaust Gasket replacement |
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.
--------
Cristal Waters
Kolb Mark II Twinstar
Rotax 503 DCSI
Read this topic online here:
http://forums.matronics.com/viewtopic.php?p=235083#235083
Message 3
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| Subject: | Re: 503 Exhaust Gasket replacement |
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
--------
LS
Titan II SS
Read this topic online here:
http://forums.matronics.com/viewtopic.php?p=235086#235086
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