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rotax two stroke rebuilds

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hi all


could someone enlighten me as to what a zero hour rebuild on a rotax two stroke actually incorporates ?


does a top rebuild qualify or is it also necessary too rebuild the bottom end


It seems to me that there is no set crteria,


Life is mostly froth and bubble


two things stand like stone


kindness in anothers trouble


and courage in your own.


not mine percy



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Guest TOSGcentral

I have done a few of these (the last one was last week).


There are a number of factors involved that you need to understand.


A basic ‘zero hour’ rebuild will be a TOTAL strip of the motor and basic shell components thoroughly cleaned and inspected.


For a ‘zero hour’ you will get new pistons, rings, what few gaskets


there are, con rods, gudgeon pins/bearings, new heavy duty crank, new


main bearings and con rod bearings.


This should normally include benching the stator and checking that out


fully. You will usually find that you end up with new HT


leads/caps/plugs as well.


If in the hands of a responsible person then you will get a zero hour engine back that you can rely on.


But there are of course peripherals! Cooling system (532 & 582),


Reduction gear boxes, and starter motor. These are NOT part of ‘zero


hour’ engine but are best done at the same time. They can all be


checked and measured with corrections as needed.


You should note that this process is expensive – mainly in parts. It


would appear that Rotax got pissed off with an enduring poor reputation


and stopped supplying component parts. Many of these require specialist


tooling and presses. A few back yarders thought they knew better and


the failures continued unnecessarily.


So, for example, you cannot rebuild a crank yourself – you get an


entire new assembly with rods already attached etc which can then be


put in the crankcase.


To dissuade you further – over the last few years prices have escalated


something fierce along with the excision of all but one Rotax agent –


Bert Flood. The situation has nearly got to the point where it is


nearly as cheap to buy a new basic motor than zero hour an existing


one. I can see Rotax’s point but it was only a few years ago I was


looking at about $2500 for a good rebuild and now it could be up to


$3500 or more! Bit sad but there you go.


I get all my engines done by Richard Eacott at Boonah (who has been through the Rotax factory courses in Austria)


and stays bang up to date. He will also give you a wealth of advice to


steer you in the direction you should go including fault finding.


Absolutely no bullsh*t from Richard! You can get him on 07 5463 2476







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Guest micgrace

Hi tony,


I believeit was possibleto obtain a rebuilt crankshaft for 503/582 at one time.


I can't recall of it being mentioned nowdays. Anyone have any info?





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Guest TOSGcentral

Yes you can get the cranks - but they now come as complete, assembled


sets - you cannot get the bits and put them together yourself because


they have to go in special presses and that is what Rotax apparently


kicked up about!


I do not know of 're-built cranks' - never heard of them, so I would suspect not!


You can still get the separte bits to do a top end overhaul yourself -


pistons, rings, gudgeon pins, bearings etc, plus re-hone the bores







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Guest micgrace

Hi Tony.


I have actually seen a professionally rebuilt crankshaft. I couldn't recall who did it. Should have taken some notes.





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Guest micgrace

Hi again.


I checked out the rotax parts catalogue. You are right. No overhaul parts available for crankshaft. Such a pity.


Which means whoever was selling reconditioned crankshafts would no longer be doing it.


I notice only 2 rebores available as well. depending on condition, probably effectively one only




would almost be tempted to obtain a new engine each time, rather than a


rebuild under these conditions. I don't think there are much savings to


be had, especially as all ancillary equipment would need overhaul at


same time.


For those who are interested in the current parts catalogue, the link is




It's nearly 400 page file, so forget it without broadband. It's in German/English





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