Saturday, December 4, 2010

Points Ignition Rotax 447 Op. Manual #26,38

Maintenance manual from Skydrive which I hoped covers the older 'points ignition' 447 engines 'Repair Manual' for the points ignition Rotax 447,  is a bit vague & actually the only reference to 'points' is in the title !

Graham Smith lent me his 'Operator's Manual' for the 447 with points ignition, for me to copy, its in Word now to reduce its Kb's but still quite a lot. If Graham doesn't mind I could e-mail selected pages if you need a copy.(  mikehallam@btinternet.com  )
Here's the text only
Points type IGNITION SYSTEM
The ROTAX engine is equipped with a BOSCH magneto generator of 12V 140W rating, producing the current necessary for the ignition and accessories. The ignition unit has been set to precisely by the factory. After initial break-in adjustments make no changes unless absolutely necessary.
In case of trouble observe the following:If the ignition fails intermittently or if there are other troubles that are due to neither spark plug, nor external components, nor carburetor, the contact breakers may be the cause. Contacts must be clean and must not be burnt. With new engines or new points the cam-follower of the ignition point set wears rapidly initially. Resetting of contacts may therefore be necessary after same time. The breaker contacts are accessible after removal of the rewind starter and the starting pulley. The magneto housing need not be removed. Once cam follower has "polished in" and points are re-adjusted, settings will hold for considerable time. To check whether the ignition timing is correct there is an arrow on the fan housing. Further, there are two scribe marks on the magneto housing, one for each cylinder. When the scribe mark for the cylinder concerned lines up with the arrow, the ignition points should just have broken contact, thus triggering the ignition spark. If settings are correct, this would correspond to a firing point with a tolerance of between 1.$3 and 2.33 mm or .072 and .092 inch in piston movement before the piston reaches the top of the stroke, Use a dial indicator tool installed in the spark plug hole.IGNITION TIMING (marks procedure)
1) Disconnect spark plug wires and remove spark plugs.
2) Remove rewind starter assembly from engine, then remove the fan protector and starting pulley.
Note: The upper breaker point set controls the timing of the magneto side piston and the lower breaker point set controls the P.T.O. side piston.
3) Rotate crankshaft until breaker points visible through flywheel are fully opened. Adjust point setting to .012 to 0.015 inch using a feeler gauge and screw driver. Repeat procedure for other set of points. Adjust both sides equally.
4) Pull back the rubber boot from the double lead wire from both external coils. Connect one end of a timing light (flashlight type) or a tone timer to the double lead wire connection (mag side). Connect the other wire to a good metal connection on engine (ground).
5) Turn timing instrument on. Insure that ignition switch is on. Rotate crankshaft until mag side piston approaches top dead centre and timing marks align. The timing light should fluctuate or tone signal vary. If not, then slacken the two armature plate retaining screws and rotate the plate till marks and timing fluctuation align, then retighten retaining screws.
NOTE:6) Disconnect timing instrument wire from mag side connection, then reconnect it to the double wire connection on power take off coil wire leading from engine. Rotate crankshaft until PTO side piston approaches top dead centre. As soon as timing marks align, timing light should fluctuate, or tone signal sound level should vary.
NOTE:
- if timing is too early, decrease breaker point gap toward lower limit, i.e. 0.35 mm ( .014"), then recheck timing,
- if timing is too late, increase breaker point gap If necessary to adjust, proceed as follows: Timing may change upon tightening screws. Recheck and correct as necessary.
NOTE toward upper limit, i.e. 0.45 mm ( .018"), then recheck timing.

7) When correct timing is achieved, check pole shoe breakaway gap. The gap must be within 8 to 17 mm or 0.3 to 0.69 in. when the mark on flywheel corresponds with mark on fan housing.
If the break-away gap is out of tolerance, the flywheel may have turned on the crankshaft. Remove flywheel and inspect taper and key. Repair if necessary.
8)Once completed, reconnect all wires, replace "V" belt pulley and starter cup. Replace rewind starter and fan protector.NOTE: Mag and P.T.O. coils are wired inversely for correct output of ignition. If in doubt, check wiring diagram.

Too early: Turn armature plate clockwise to Decrease point gap.Too late: Turn armature plate counter-clockwise to Increase points gap .
: Breaker point gap can change upon tightening. Always recheck after tightening.

1 comment:

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