Rotax 462 Service, Repairs & Info!


AeroFix Aviation offer a mobile maintenance service with a fully equipped mobile workshop AND a fully equipped static workshop (by prior arrangement).

All our fixed-price scheduled servicing work is completed along with a detailed Workshop Report Sheet of the work carried out if requested.

Rotax 462 Engine Service - What's included? ...

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Rotax 462 Gearbox Servicing ...

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Rotax 462 Engine Shock Load Test / Prop Strike Inspection ...

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Rotax 462 Carburetor Clean / Overhaul Service ...

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Adhoc Rotax 462 Maintenance, Servicing, Repairs ...

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Rotax 462 Technical Specifications ...

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Rotax 462 Problems / Troubleshooting ...

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Rotax 462 Engine Service - What's included ...

10 Hour Engine Service (Initial 10 Hours Only)

  • Re-torque cylinder head nuts
  • Re-torque exhaust manifold screws
  • Re-torque gearbox fasteners
  • Check / adjust ignition timing as neccessary / if applicable
  • Check security of condensors (if applicable)
  • Check condition of points (if applicable)
  • Check condition and test resistance of generator coil
  • Test operation of damper box (if applicable)
  • Checking of v-belt tension - reshim as necessary
  • Check carburetor(s), adjust idlespeed / cable tension
  • Inspect carburetor needle
  • Replace gearbox oil
  • Inspect carb rubber(s)
  • Inspect air filter
  • Inspect fuel filter

Pricing for 10 Hour Service

Item: Price:
Labour (only) £150.00
Gear Oil API GL5 LUB-035 (if req'd)
EP80W-90 Suitalble for Rotax
A, B, C or E type gearboxes.
add £9.60

12.5 Hour Engine Service (Initial 12.5 Hours Only)

  • Inspect re-wind starter rope (if applicable)
  • Inspect spark plugs
  • Inspect and clean inside Spark Plug caps

25 Hour Service - Every 25 hours

  • Check ignition system
  • Inspect and clean inside Spark Plug caps
  • Checking of v-belt tension - reshim as necessary
  • Lubricate exhaust ball joints
  • Lubricate throttle and choke cables
  • Check carburetor(s), adjust idlespeed / cable tension
  • Check Propellor gearbox oil level
  • Ground run if engine is in aircraft
  • EXTRA COST ITEM - Replace spark plugs
  • EXTRA COST ITEM - Replace fuel filterr
  • EXTRA COST ITEM - Check propeller balance
  • EXTRA COST ITEM - Clean and oil air filter
  • EXTRA COST ITEM - Replace propeller gearbox oil
  • EXTRA COST ITEM - Perform CCBBCT - Cyclone Conrod Bearing Clearance Test

Pricing for 25 Hour Service

Item: Price:
Labour (only) £150.00
Spark Plugs B8ES (each) add £3.65
Spark Plugs BR8ES (each) add £2.65
Fuel Filter add £3.31
Check propeller balance - hourly labour rate applies add £32 /hour
Clean and oil air filter add £11.99
Gear Oil API GL5 LUB-035 (if req'd)
EP80W-90 Suitalble for Rotax
A, B, C or E type gearboxes.
add £9.60
Perform Cyclone Conrod Bearing Clearance Test add £20.00

50 Hour Service (Every 50 Hours) - Everything in a 25 Hour Service plus ...

  • Inspect electric starter gear (if applicable)
  • Check / adjust ignition timing (if applicable)
  • Check security of condensors (if applicable)
  • Check condition of points (if applicable)
  • Check condition and test resistance of generator coil
  • Test operation of damper box (if applicable)
  • Disassemble, clean carburetor(s) and check for wear
  • Inspect carb needle
  • Insect carb sockets
  • Inspect cylinder head and piston crown
  • De-coke piston / pistons rings
  • De-coke cylinder exhaust port
  • Inspect piston pin and small end bearing
  • Measure piston diameter
  • Measure piston ring gap
  • Measure piston ring flank (groove) clearance
  • Measure piston pin and small end bearing
  • Measure cylinder diameter
  • Measure cylinder roundness
  • Perform CCBBCT - Cyclone Conrod Bearing Clearance Test
  • Replace items in SkyDrive de-coke gasket set
  • EXTRA COST ITEM - Replace needle bearings (especially recommended if caged bearings are installed)
  • EXTRA COST ITEM - Replace spark plugs

Pricing for 50 Hour (DECOKE) Service

Item: Price:
Labour (only) £220.00
Genuine Rotax 462 Decoke Gasket Set add £65.05
Cageless Needle Bearing (set of 2) add £65.20
Piston circlips (set of 4) add £1.00
Spark Plugs B8ES (each) add £3.65
Spark Plugs BR8ES (each) add £2.65
Fuel Filter add £3.31
Check propeller balance - hourly labour rate applies add £32 /hour
Clean and oil air filter add £11.99
Gear Oil API GL5 LUB-035 (if req'd)
EP80W-90 Suitalble for Rotax
A, B, C or E type gearboxes.
add £9.60

75 Hour Service (at 75 Hour intervals) - Everything in a 25 Hour Service plus ...

  • EXTRA COST ITEM - Replace exhaust / muffler springs
  • Fuel pump function test - with fuel pressure guage

Pricing for 75 Hour Service

Item: Price:
Labour (only) £175.00
Spark Plugs B8ES (each) add £3.65
Spark Plugs BR8ES (each) add £2.65
Fuel Filter add £3.31
Check propeller balance - hourly labour rate applies add £32 /hour
Clean and oil air filter add £11.99
Gear Oil API GL5 LUB-035 (if req'd)
EP80W-90 Suitalble for Rotax
A, B, C or E type gearboxes.
add £9.60
Perform Cyclone Conrod Bearing Clearance Test add £20.00
Replace exhaust / muffler springs (each)
(75mm hook distance)
add £5.20

100 Hour Service (Every 100 Hours) - Everything in a 50 Hour Service plus ...

  • EXTRA COST ITEM - Replace fuel filter
  • Re-torque gearbox adapter bolts if A gearbox is fitted.
  • EXTRA COST ITEM - Full gearbox service if A or B gearbox is fitted.

Pricing for 100 Hour (DECOKE) Service

Item: Price:
Labour (only) £220.00
Genuine Rotax 462 Decoke Gasket Set add £56.05
Cageless Needle Bearing (set of 2) add £65.20
Piston circlips (set of 4) add £1.00
Spark Plugs B8ES (each) add £3.65
Spark Plugs BR8ES (each) add £2.65
Fuel Filter add £3.31
Check propeller balance - hourly labour rate applies add £32 /hour
Clean and oil air filter add £11.99
Gear Oil API GL5 LUB-035 (if req'd)
EP80W-90 Suitalble for Rotax
A, B, C or E type gearboxes.
add £9.60
Re-torque gearbox adapter bolts if A gearbox is fitted
included in the price of a Type A Gearbox service
If not having gearbox service ...
add £25.00
For Type A or B gearbox service info and prices ...
please see here Rotax 462 Gearbox Servicing ...

150 Hour Service (at 150 Hour intervals) - Everything in a 50 or 100 Hour Service (as applicable) plus ...

  • EXTRA COST ITEM - Replace points and condenser (Bosch Ignition only)
  • EXTRA COST ITEM - Replace jet needle and needle jet
  • Full engine strip to inspect crankshaft
  • EXTRA COST ITEM - Replace crankshaft seals if required

Pricing for 150 Hour (CRANK INSPECTION / DECOKE) Service

Item: Price:
Labour (only) £395.00
Genuine Gasket Set for Rotax 462 (with A type gearbox)
Includes all gaskets, oil seals, O rings etc
add £106.66
Genuine Gasket Set for Rotax 462 (with B type gearbox)
Includes all gaskets, oil seals, O rings etc
add £118.20
Cageless Needle Bearing (set of 2) add £65.20
Piston circlips (set of 4) add £1.00
Capacitor Set (Condensors) (set of 2) add £42.20
Contact Breaker Set (Points) (set of 2) add £52.04
Spark Plugs B8ES (each) add £3.65
Spark Plugs BR8ES (each) add £2.65
Fuel Filter add £3.31
Check propeller balance - hourly labour rate applies add £32 /hour
Clean and oil air filter add £11.99
Gear Oil API GL5 LUB-035 (if req'd)
EP80W-90 Suitalble for Rotax
A, B, C or E type gearboxes.
add £9.60

Pricing - On strip-down and inspection it may be discovered that other parts are required. Please phone to discuss.

300 Hour Service (at 300 Hour intervals) ...

  • General Engine Overhaul

Pricing for 300 Hour (CRANK REPLACEMENT / DECOKE) Service

Item: Price:
Labour (only) £395.00
Genuine Gasket Set for Rotax 462 (with A type gearbox)
Includes all gaskets, oil seals, O rings etc
add £106.66
Genuine Gasket Set for Rotax 462 (with B type gearbox)
Includes all gaskets, oil seals, O rings etc
add £118.20
Cageless Needle Bearing (set of 2) add £65.20
Piston circlips (set of 4) add £1.00
Capacitor Set (Condensors) (set of 2) add £42.20
Contact Breaker Set (Points) (set of 2) add £52.04
Spark Plugs B8ES (each) add £3.65
Spark Plugs BR8ES (each) add £2.65
Fuel Filter add £3.31
Check propeller balance - hourly labour rate applies add £32 /hour
Clean and oil air filter add £11.99
Gear Oil API GL5 LUB-035 (if req'd)
EP80W-90 Suitalble for Rotax
A, B, C or E type gearboxes.
add £9.60

Pricing - On strip-down and inspection it may be discovered that other parts are required. Please phone to discuss.

Rotax 462 UL Technical Specifications

GENERAL DESCRIPTION: Two cycle, two cylinder, rotary valve engine,
oil-in-fuel lubrication,
liquid cooled, with integrated water pump
BORE: 69.5mm (2.736 in.)
STROKE: 61mm (2.401 in.)
DISPLACEMENT: 462.8cc (28.242 cu. in.)
COMPRESSION RATIO: Theoretical 11.5, effective 6.7
POWER OUTPUT: Extra Silent Version:
(Low Performance):
28.0kW (38 HP) at 5,500 rpm
Standard Version:
38.0kW (52 HP) at 6,500 rpm
TORQUE MAX.: 52.0 Nm at 5,250 rpm
56.0 Nm at 6,000 rpm
MAXIMUM RPM: Low Performance Version:
5800 RPM
Standard Version:
6800 RPM
DIRECTION OF ROTATION Counter-clockwise, viewed towards PTO
(without reduction gearbox)
CYLINDER: 2 light alloy cylinders w/ cast iron sleeves
PISTON: Aluminum cast piston with 2 rings
IGNITION SYSTEM: Bosch SCP2 Points / Contact Breaker
with magneto generator.
GENERATOR OUTPUT: AC 12V 110W + 30W
RECTIFIER-REGULATOR:
(optional)
Option A) p/n 866080 requires minimum load
of 12 W (1 amp.)
Option B) p/n 264870 requires no minimum load
IGNITION TIMING: 1.96mm (+/- 0.25mm)
(.077"+/- 0.01")
18°BTDC
CONTACT BREAKER
(POINTS) GAP:
0.3mm - 0.4mm
(.012" - .016")
SPARK PLUG: 14mm NGK
B8ES (non resistive)
BR8ES (resistive)
ELECTRODE GAP: 0.5mm (.02")
ROTARY VALVE:
Cut off Section
Low Performance 117°
Standard Version 147°
ROTARY VALVE TIMIMG: Low performance version:
Opens 120° BTDC)
Closes 40° ATDC)
Standard version:
Opens 140° BTDC)
Closes 51° ATDC)
ROTARY VALVE
LUBRICATION:
Oil Bath
Super 2-stroke oil
CARBURATION: 2 X BING 54 (36mm),
with hand lever choke
FUEL PUMP: Pneumatic fuel pump DF 52
FUEL: Regular gasoline,
octane not below 90 unleaded
LUBRICATION OF ENGINE: Super 2-stroke oil
MIXING RATIO: 50 TO 1 (2%)
STARTER: Rewind starter
Optional: Electric mag side without recoil option
GEARBOX OIL: Gear oil API-GL5 or GL6,
SAE 140 EP or 85W - 140 EP
REDUCTION GEARBOX "A"
(Prov 4 Crankcases only)
Reduction gear-box with Torsional shock absorber
RATIOS: 2.00 to 1
2.238 to 1
2.58 to 1
DIRECTION OF PROP
ROTATION:
Clockwise, viewed toward prop flange
COOLING: Liquid cooled
FUEL PRESSURE: 0.2 - 0.5 bar (3 - 7 PSI)
MAX COMBUSTION
CHAMBER DEPOSITS:
0.5 mm (0.02")

Adhoc Rotax 462 Maintenance,Servicing,Repairs ...

As well as offering the above Rotax 462 Servicing as part of your recommended routine maintenance plan we are available for other more adhoc maintenance / servicing work e.g. miscellaneous troubleshooting / fault finding work etc.

Rotax 2-Stroke Engine Strip, Inspect and Rebuild / Repair.

We offer a full Strip, Inspect and Rebuild / Repair service on Rotax 2-stroke engines (including gearbox) in the event that your Rotax 503 may have been damaged e.g. suffered a hot or cold siezure or involved in an incident. We are only able to reasonably accurately estimate the work and parts involved (and therefore the cost) of the rebuild once the engine has been striped and inspected as an initial step. For crankshaft changes / complete rebuilds our preference will always be to do this work in our workshop facility rather than on-site if possible. This is because if if the strip down indicates that unexpected parts are required then we would prefer that your engine were safely on our workshop bench rather than being left at your airfield in a dissassembled state exposed to the elements. You can either bring the engine to us or we can come and remove it from your aircraft / collect it to bring it back to the workshop. If your engine is fitted to a flexwing trike or other road-transportable aircraft then you are welcome to trailer it to us thus saving you the cost of us coming to collect it. Please phone to discuss.

Our Hours:

The mobile is normally answered during the following times ...

Monday - Friday: 8:30 am - 7:30pm

Saturday: 7:30 am - 1.00pm

Please leave a message as we may be unable to answer. We will call you back!

AeroFix Aviation
Higher Wilson Fold Farm
High Rid Lane
Bolton
Lancashire
United Kingdom
BL6 4LH
Telephone: 07779 147 229
E-mail:
Enquiries@AeroFixAviation.co.uk