RTX 618UL LOCKWOOD AVIATION SUPPLY 1 LOCKWOOD LANE SEBRING, FL PHONE: FAX: kwood-a. viation Supply.

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1 LOCKWOOD AVIATION SUPPLY 1 LOCKWOOD LANE SEBRING, FL PHONE: FAX:

2 CRANKCASE, c ROTARY VALVE SHAFT WATER PUMP UL R Ill No Part# Description Crankcase assy Lock washer A Allen screw M8x75, 24NM collar hex screw M8x65,24NM Allen screw M8x65,24NM Allen screw M8x45, 24NM Lock washer A Allen screw M6x45, 10NM Gasket ring 6x Hex screw M6x10, 8NM Angular tube npt Stud M10x29/20, 12NM Lock washer A Hex nut M10, 38NM Retaining ring 30x Ball bearing Z, Oil seal A 12x30x7 NBR Rotary valve shaft Oil seal 20x40x Ball bearing 6203 TVH C Shim 17.2/32.5/ Retaining ring 17x Spacer O ring Rotary valve gear 14T Compression spring, 25.1mm Spring holding cup Circlip Rotary seal O ring 8x Rotary seal sleeve Friction washer Impeller Washer Lock nut M6, 7NM Gasket Water pump housing,mount venting screw down Gasket ring 6.2/8.9/ Hex screw M6x Hose nipple M6,for bleeding air out when engine is inverted Washer Hex screw M6x25, 8NM Snap ring 40x Rotary valve, 151 degree Cable clamp 15/M Washer A Mass cable assy Lock washer, A Allen screw M5x Cageless bearing label Loctite 574, orange As Rqd 52 LT680 Loctite 680, green As Rqd 53 LT222 Loctite 222, violet As Rqd 54 BP Energrease As Rqd EXHAUST SYSTEMS 41

3 OIL TANK, IGNITION COILS SUPPORTING PLATE Supporting plate Clamp 20mm Grommet Washer Electronic box, circuit 1,pto side Lock washer A Protection cap Hex screw M8x Ignition circuit 1, 360mm Washer Faston connector, 6.3x Lock washer A Electronic box, circuit 2,mag side Allen screw M6x Ignition circuit 2, 440mm Connector housing Ignition circuit 2, 180mm Connector housing Spark plug connector,magenta Shrink hose, 40mm As Rqd 11 B8ES Spark plug, 14mm, 27NM COLD Faston connector 6.3x Hex screw M6x25, 5NM Connector sheath, yellow As Rqd Washer Faston connector 6.3x.8 As Rqd Lock nut M6, 8NM Faston connector 6.3x.8 As Rqd Protection hose, 170mm Connector sheath As Rqd Oil tank assy Cable terminal M5 As Rqd Rubber gasket 26.5mm Cable shoe M4 As Rqd Oil tank cap Cable shoe M3 As Rqd x18mm oil line, 155mm 1 42 LT680 Loctite 680, green As Rqd x18mm oil line, 360mm Lithium based grease As Rqd Clamp Silastic 732 RTV As Rqd Rubber spacer Clamp 100mm 1 42

4 R INSTALLATION OF CRANKSHAFT: Always pay attention to cleanliness. Small amounts of foreign matter in the oil circuit could cause severe damage or reduce the lifespan of the engine essentially. Lubricate all bearings and moving parts in the coarse of assembly. All o rings, oil seals and gasets must be renewed at re-assembly. 618UL CRANKSHAFT,PIST,PISTONS The axial position of the crankshaft is predetermined by the two ball bearings at the crankshaft center with one each locating ring engaging in the #1 groove of the crankcase.fitting and completing of crankshaft assembly generally in reverse sequence to disassembly. Clean and degrease all bearing seats. The ball bearings are furnished with an o ring on the circumference, to avoice possible rotation of the outer race in the crankcase. To prevent squeezing of the o-rings when joining the crankcase halves, clearances (#2) are provided on jointing face of crankcase. Place bearings on crankshaft with the o rings located in clearances. Warm up ball bearings to 70-80C ( F). Properly preheated bearings can be fitted easily onto jounals of crankshaft. See following chart for proper lubricants/adhesives and where they are applied. ASSEMBLY OF CRANKCASE: Take apart crankcase again, still assembled for taking readings of dimentions. Pre-heat crankcase to 70-80C ( F). Press bearint for rotary valve shaft on waterpump side into position, using punch # and secure bearing with retaining ring 32x1.2. Closed side of ball bearing to pint towards inside. This retaining ring is used on 532 s starting with # , 582 s from and all 618 s. To facilitate assembly, support upper half of crankcase on cylinders with the sleeve spigots projecting into crankcase half. Place crankshaft with conrods down into crankcase. Push oil seals at crankshaft centre outwards onto ball bearings. Ensure that the retaining bead comes to rest in the assigned groove in the crankcase. Push outer oil seals also against ball bearings. The retaining bead of the oil seal on PTO side has to fit into the provided groove in the crankcase. Join crankcase halves as previously stated above. Tightening torque for case screws is: M6-10NM (90 in lb), M8-24NM (210 in lb.) Check crankshaft for proper alignment before assembling crankcase. Prior to tightening of crankcase screws, align the two halves on the face at PTO side, utilizing a straightedge or by running a finger accross the joint. If need be, align by using a rubber mallet. Finally, lift crankcase assembly from support, turn upright and relieve stress in the bearings by a light blow with a rubber mallet. Crankshaft must turn freely now. Check with a few rotations cranking on on connecting rods. If crankshaft won t turn freely, disassemble crankcase again and rectify. Once crankcase is assembled, secure connecting rods to prevent damage to sealing surfaces. Lubricate all bearings of crrank and the spiral gear drive of the rotary valve shaft sufficiently with 2-stroke oil. Apply to oil ducts in crankcase as well. EXHAUST SYSTEMS Crankshaft assy, 68mm stroke Crankshaft Distance ring 31/42/ Ball bearing 6206TVH Retaining disk Oil seal 30x62x7/ Distance ring 35.5/47/ Ball bearing 6207NTNHC O ring Labyrinth sleeve O ring Retatining disk Oil seal 35x72x7/ Lock washer Hex nut M22x Woodruff key 3x Cageless bearing Thrust washer 18/21.7/ Piston w/rings,75.94/95mm Piston w/rings,76.19/20mm Piston w/rings,76.44/45mm Rectangular ring, 76mm Rectangular ring, 76.25mm Rectangular ring, 76.5mm Semi trapez ring, 76mm Semi trapez ring, 76.25mm Semi trapez ring, 76.5mm Piston pin 18x10x Circlip PSAS Anti seize As Rqd 24 LT222 Loctite 222, violet As Rqd Lithium based grease As Rqd 43

5 CYLINDERS,HEAD Dual base gasket Cylinder w/sleeve, 76.0/ Collar hex screw M8x90, 24NM O ring Rubber gasket Stud M8x75, 7NM Stud M8x84, 7NM Cylinder head, 11.5 comp ratio Cap nut M8, 22NM Thermostat w/gasket Thermostat 55 degree Thermostat gasket Bent outlet socket Lock washer A Hex screw M6x20, 10NM Gasket Bent outlet socket Plug screw 1/8-27npt, 6NM Gasket ring 6.2/8.9/ Hose nipple, M6, 8NM Hex screw M6x8, 8NM Valve rod, 1.5NM Hex nut BM6, 10NM Washer Exhaust valve O ring 6x Exhaust valve gasket Valve rod housing Spring washer B Allen screw M6x16, 10NM Pipe bend Hex nut M7x Hex nut M6x Adjustment screw M6x Bellows clamp 20mm Exhaust valve piston Hose spring Valve lever Spring Compression spring 42mm Adjustment screw Valve cotter Spring clip Molded hose 25/180 degree Clamp Intake silencer bracket Silastic 732 RTV As Rqd 48 LT222 Loctite 222, violet As Rqd 49 LT680 Loctite 680, green As Rqd 50 BP Energrease As Rqd NOTE: It is recommended to clean rave valves every 50 hours and hook up as to cycle every flight. If valves do stick, engine power drops to that of a 582

6 R ROTAR ARY VAL ALVE COVER,OIL INJECTION INTAKE O ring Rotary valve cover assy Drive pin 5x Washer Lock washer A Hex screw M8x25, 20NM Hex screw M8x20, 20NM Rubber ring, 126x1.5x Pump mounting flange O ring Oil pump assy Wahsher 6.2/12/ Oil pump gear 44T Lock nut M6, 5NM Lock washer A Slotted head screw M5x16, 5NM Lock washer A Hex screw M6x20, 10NM Gasket ring 6.2/12/ Check valve assy Banjo bolt M6x16, 8NM Oil line, 230mm Clamp 3-5mm Clamp 62mm Carb socket Hose clamp, 53mm 2 27 FF0-125 Oil filter 1 EXHAUST SYSTEMS 28 LT222 Loctite 222, violet As Rqd Lithium based grease As Rqd DUCATI TI MAGNET GNETO O GENERATOR 12V 170W Magneto generator 12W Magneto flywheel, to Magneto flywheel, Coil kit, 12W Stator plate assy Stator plate Lock washer A5 5 Ill No Part# Description Ill No Part# Description Allen screw M5x30, 6NM Harness assy, 12W Washer Allen screw M5x18, 6NM Trigger coil, circuit Insulation sheath Faston connector Trigger coil, circuit Insulation sheath Faston connector Taptite screw M5x16, 6NM Washer, A Liquid damper assy, Lock washer Hex nut M22x1.5, 95NM Starting pulley, to Starting pulley, Lock washer A Hex screw M8x16,to Hex screw M8x20, Spiral hose 70mm Cable grommet 20.4/ Faston connector 6.3x Insulating varnish As Rqd Lithium based grease As Rqd 28 LT222 Loctite 222, violet As Rqd 29 LT680 Loctite 680, green As Rqd 618UL 45

7 46 OR NOTE: Oil injection line available in 5 lengths, # , $9.95/ft ROTAR ARY VAL ALVE COVER INTAKE FLANGES O ring Rotary valve cover assy Drive pin 5x Washer Lock washer A Hex screw M8x25, 20NM Hex screw M8x20, 20NM Rubber ring 126x1.5x Pump mounting flange O ring Oil pump assy Washer 6.2/12/ Oil pump gear 44T Lock nut M6, 5NM Lock washer A Slotted head screw M5x16,5NM Lock washer A Hex screw M6x20, 10NM Gasket ring 6.2/12/ Check valve assy Banjo bolt M6x16, 8NM Oil line 230mm Clamp 3-5mm Clamp Carb socket Clamp 53mm Oil filter 1 28 LT222 Loctite 222, violet As Rqd Lithium based grease As Rqd Following items are only used if oil injection pump is removed Block off plate gasket Block off plate asher A Hex screw M6x20, Slotted head screw M5x16, LT222 Loctite 222, vioet As Rqd DUAL AL INTAKE SILENCER WITH MOUNTING FRAME & HARDWARE Intake silencer w/frame 1 Inner plastic tubes Intake silencer assy 1 (not shown)# Frame Rubber 20x10x Washer Hex screw M6x Lock nut M Intake silencer bracket MS Intake solencer bracket AS Lock washer A Hex scre M8x Lock washer A6 2 COMPLETE KIT Distance bar , # Protection hose Rubber buffer, 25x20xM Intake silencer bracket Silencer socket Clamp CM0300 Air cleaner Air cleaner cap 1

Rotax 447 CDI - 40 HP

Rotax 447 CDI - 40 HP 999-667...Info Pak...$10.00 Refundable with purchase of engine 447 UL-1V : 39.6 HP @ 6300 447 UL-2V : 41.6 HP @ 6500 2 Cylinder / 2 Stroke Piston Ported, fan cooled, electronic single-ignition,