The oil
pipe used from the reservoir was very stiff and I found it pushed hard against
the front carb throttle bush. Mainair fixed this on inspection and found that it
was a fault on other engines they had readied to go out so was modified.Engine and Radiator
Now the trike is pretty much done, I moved onto the engine.
When you have the engine on the mount and find on trying to locate it on the mast and lower supports that it doesn't fit... I was supplied with a mount for a 503, and not a 582, which after much straining I twigged! To be fair this was only the second wrong component!
Be wary of the location and sizes of lord mounts. The front right upper mount is different to all the others. I had trouble with the M4 fixings used to locate the lord mounts, and sheared 6 out of 16. Some had broken overnight, and some when I went to remove them. On destruction testing a couple they seemed unusually brittle, and are infact just zinc coated steel. Anyway I replaced them all with stainless as I was far from happy. Roger at Mainair was at a loss to explain what had happened as they use a lot of them with no trouble. I'm pretty confident I didn't over tighten them!
The rubber bumpers on the lower engine mounts proved fiddly. These are to protect the engine studs from the tank. They are D shaped rubber channels that fit over the studs then from the inside you place a washer and nyloc. I realised afterwards that you can put the washer on, then push the nyloc in and onto the stud and use a screwdriver to turn the nut around a couple of threads. Once this has been done you can force a socket head in to tighten. It does work!
Another problem was that the bracket that mounts the rear coil interfered with the upper rear lord mount nut. I fettled the top of the bracket to give adequate clearance. Roger said that this is a new type bracket used by Rotax.
The oil
pipe used from the reservoir was very stiff and I found it pushed hard against
the front carb throttle bush. Mainair fixed this on inspection and found that it
was a fault on other engines they had readied to go out so was modified.
The
large rear radiator, the one the right looking from the rear had the top
mounting spigot soldered in 5 degrees out which caused mounting problems, and
the radiator just wouldn't hang squarely. Note the mounting for the radiator is
a mix of hot climate and not in the manual assembly. Hopefully the pictures will
help you here!
When
fitting the water hose from the water pump to radiator allow sufficient room to
cleanly remove the EGT sensor as the pipe can get in the way. It does on mine,
but I can just remove it!
Note the upper support wires to the top of the mast should be loose on the top engine mount.
The lower radiator pipe caused a problem due to the radiator not hanging correctly, but was rectified by Mainair on inspection. I used self amalgamating tape, (thanks Colin), around the lower pipe to fix an outer pipe to for support. The pipe had to have an inner alu sleeve inserted. This WAS a pig, but again Colin to the rescue and he disappeared indoors muttering something about KY jelly. Nuff said!!! The lower mounting bracket also required some work to get a nice clearance around the bottom of the engine.
The fuel tap now uses an extension bracket to make it easier to reach in flight. This part is not in the kit. Mainair fitted it on inspection