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Rotax strip / re-build
Topic Started: Jul 10 2016, 06:49 PM (831 Views)
Ant P
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I decided today was the day to strip down the rotax after sprag meltdown 3. Spoke to Gary @Sportax and he had the replacement sprag and freewheel in stock. Happy days. Oil was already drained as i need to remove seized exhaust bolt from head. After taking sump plate off i found most of the sprag in there and attached to the magnet.

So as the lump is pretty grubby and i want to sort this properly i got to thinking i might remove the engine and do a proper job of it with new gaskets, bearings etc. Has anyone seen or posted strip down advice online? Ive heard the swingarm /frame fitting is a pain but not phased as i poss want to fit a longer swingarm ive bought then get hold of off road wheels and poss the longer suspension to suit. Any pointers? Also is the clutch oil recovery mod worth doing while its in bits or would i potentially make the engine less reliable? Thanks
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jonny h
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this is how i roll!
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all the suspension is the same, unless you have a lowered version?
if you're planning on trail riding or a bit more technical off roading, then yes i would do the clutch basket mod.
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,C26 604e, Posted Image

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Ant P
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Think i have a lowered version. Shock has no piggyback and i can stand over it easily at 5'10"?
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Ant P
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Rotax stripped, piston and liner polished, valves to clean then remove seized snapped stud. Is there a trick to fitting piston back in liner?

Rings seem to make it difficult and dont want to force anything and risk damage?
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MountainPirate
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Single pot is easy enough to put back together, just squeeze each ring in turn as you slip the piston into the liner. Can be a bit fiddly, but at least you haven't got an inline-4. :-p

MP
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stevo604
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God
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I used a large cable tie to clamp the rings and went in easy enough ,have a piston clamp aswell but the cable tie was quicker
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Ant P
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Cheers Stevo will defo give that a try. Sounds much better than trying to do by hand
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Ant P
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Cable tie trick worked a treat! Barrel polished and attached! Port polish next
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stevo604
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God
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Ant P
Aug 10 2016, 12:24 PM
Cable tie trick worked a treat! Barrel polished and attached! Port polish next
glad you got it sorted
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Ant P
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Its been a while but finally had time! Head stripped. Ports etc polished. Seized exhaust stud removed via careful time consuming drilling. Got o rings from Monty. Need to get some parts from Gary then re build can commence. Only worry is previous sprags have been ran round the engine/frame. Is it worth rebuilding without sprag etc running some cheap mineral oil through to clear any left overs?
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