Rotax engine tools, Rotax engine special tools, Rotax 503, Rotax aircraft engine rebuilding manual. |
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| Special tools required | |||||||||||||||
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Magneto puller Two part puller used to pull magneto on all Rotax points ignition systems. |
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876 950 Dial
indicator |
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| Alignment bar(s) Used to align cylinders prior to torquing heads on 503/582 Rotax ultralight engines. Cylinder alignment tool 876 570 ( You can also place the cylinder head on upside down to align cylinders.) |
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 Wrist pin clip insertion toolUsed to install wrist pin clips in piston on all Rotax ultralight engines. Part # 877 015 This tool is a must - while it can be done with an ice pick style probe the tool pays for itself in less "aggravation."
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| Piston fixation
- 1 required tool
a specially designed tool for holding pistons in place , when reinstalling cylinders.
(A pair of pliers with rubber coated handles will
work.) |
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 Reduction drive gear pullerUsed to pull gear on crankshaft on most Rotax ultralight engines equipped with Rotax A and B reduction drives. #276 808
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| Crankshaft locking pin A specially designed pin for locking up the crankshaft on Rotax ultralight engines. The use of any other pin for this purpose can cause severe engine damage. Part #876 640 Crankshaft fixation pin. This pin is comes with the Rotax engine tool kit. |
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 Piston pin puller
Used to remove wrist pins from piston, and install and remove cageless bearings. #877 091
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| Circlip removal tool Used to remove circlips from pistons, during disassembly of Rotax ultralight engines. ( A bent ice pick style of tool.) |
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| Mechanics tools | |||||||||||||||
Allen wrenches 4 mm required to remove stator unit 5 mm required to remove fan tower 6 mm required to remove exhaust manifold and crank bolts |
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| Feeler gauges Used to set point, and spark plug gap on Rotax ultralight engines. Used to measure ring end gap. Used to measure cylinder/piston wear. Used to measure point gap. (Brass gauges are preferred) |
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| Spark plug wrench used to remove spark plugs. Used to remove fan pulley nut. Supplied with Rotax tool kit. | |||||||||||||||
Sockets 10 mm used to remove recoil, lower shroud and crankcase bolts 13 mm used to remove top shroud bolts, intake manifold, cylinder head, and crankcase bolts. 24 mm used on magneto puller 1 3/16 "/30mm 6 point, used to remove magneto nut. Ratchet Used in conjunction with sockets in disassembly of the Rotax ultralight engine. |
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Screw drivers blade/Phillips Used to remove top of carburetor. Used to remove intake flange, adjust carburetor, adjust points, tighten carburetor clamps. Wire brush Used in the cleaning of engine parts after disassembly. Torque wrenches 1. inch lbs - 0 - 300 2. ft lbs -0 - 100 Used in torquing all the nuts and bolts during reassembly. Cylinder hone Used to remove glaze on cylinders, and install proper cross hatching pattern. Hone Oil |
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| Telescoping gauges Used to measure cylinder wall clearances. |
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| Outside micrometer. Used to measure pistons and cylinder wall clearances. |
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