Rotax 532 problem

[D Griesel]

I have an ultralight with a Rotax 532 motor.  A few weeks ago I fitted an electric starter (magneto side) to the motor.  Ever since then, I've been experiencing a serious problem in that the motor refuses to run at anything higher than 6000 rpm (previously used to go above 6400 on full throttle), and at high rpm it also surges.  When I reduce the rpm to 5800, the surging ceases, and it runs smoothly.  I have also found tht it sometimes has a dead spot at mid-throttle when opening the throttle.  From low revs it would run up, then surge, and when it comes right, it would run smoothly - except that it limits at 6000 rpm.  I need the additional rpm for take-off as I'm at a very high altitude.  It cannot be a coincidence that the problem only arose once I fitted the electric starter.  Can anyone please help !?!?
 

[mark smith]

I guess it would be easy to recommened removing the starter for a quick
check,,,,,,

but better to investigate near the starter and other areas involed in
the installation for either some problem with the fuel system or
such,,,

for example, the pulse line exits the engine near the front corner of
the engine. possibly this got damaged during the efforts on the starter.

keep us posted, trouble shooting is harder than building the stuff in
the first place,,,,,,,
--

Mark Smith mailto:tri...@trikite.com
Tri-State Kite Sales
1121 N Locust St
Mt Vernon, IN 47620 http://www.trikite.com

[Hal]

Could be you air cleaner. My 503 did the same thing until I replaced the
air cleaner. At least clean them or it.

mark smith <ma...@trikite.com> wrote in article
<3853D2...@trikite.com>...

[Scrappman]

    One thing I always do is one thing at a time, instead of doing a couple of things at once. It makes it simpler to forsure find out what step solved the problem.
                        Scrappman

[ExploreTEN]

I've got a new to me Avid with a 532 equiped with a starter. I've got no
problem yet. It winds up to 6200rpm. Very smooth.

Frank Gibney

[Kenneth Soldal]

Frank:
I just purchased a Rotax 532, and now they say the reason Rotax changed to
the 582 was because the 532 had a weak crankshaft. They had many crankshaft
failures. Have you heard any of these stories.

Thanks
Ken

[AIRSCREWS]

Well up untill a couple of years ago the 532 and 582 cranks were identical and
now they are still interchanageable and the newer 582 have more problems than
the older ones and canot be rebuilt like all the older ones can , go figure !
S.B.

[AVIDFLYER]

i think the main diff was the 582 had oil injection so you did not have to mix
it in the tank.

[AIRSCREWS]

the 532, 534 , 536 and 537 in the snowmobiles also had oil injection for 20
some yrs.
S.B.

[972]

Early 582s didn't have oil injection, that came along later. I think
there may have been water pump mods as well, but the 582 has a much
broader torque curve. 532s were very peaky and if the prop wasn't
optimum they wouldn't hold stable revs; you had to be at the throttle
all the time. If you look at the parts book there doesn't appear to be
all that much difference physically; maybe the torque curve was altered
by port timing/width changes
972.

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[Dave Loveman]

If you did not have two good grounds, one to the engine and another to
the airframe when you hooked up the electric start - when you put power
to the starter the battery may have gone looking for a ground, and
found one in the small wire that runs inside the electric harness is
usually used to ground a tach or such.
If so you may have burned the wires inside the harness, possibly back
as far as the points.
--
Dave Loveman
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