Maintenance schedule, ball joints, ball joint conversion kit

by Tim Gaffney in 2 Stroke Technical Questions 4 years ago

Hello, all-

This is my second post requesting information about the 2-stroke maintenance schedule. I’m new to Rotax engines and engine maintenance in general. I’m following the maintenance schedule in the Rotax Maintenance Manual (1999 edition) for my 503 DCDI.

Item 12, lubricate ball joints. The maintenance manual says, “all ball joints have to be greased regularly with heat resistant lubricant (e. g. LOCTITE Anti-Seize 297 434)”. I assume “regularly” means at every inspection, or every 25 hours. But what does “lubricate” mean? Wipe a few drops around the contacting surfaces? Slather it on?

Also, my engine has what appears to be the “Streamlined” exhaust ball joint conversion kit (see photo). It replaces the springs and hooks with stainless steel parts and AN hardware. Does anyone know the inspection/lubrication procedure for these joints? Am I supposed to take it apart, grease contacting surfaces, and reassemble?

Tags: Maintenance schedule, exhaust ball joints, ball joint conversion kit

8109_1_20200301-R503-exhaust-533kb.jpg (You do not have access to download this file.)

Re: Maintenance schedule, ball joints, ball joint conversion kit

by Tim Gaffney » 4 years ago

Tim Gaffney

3 6 20

After receiving no response here, I reposted my question on Rotax Owners' Facebook group. I received several replies, but I believe this one from Rotax-Owner is the most relevant. I'm copying it here for the possible benefit of others:

Here is what the Rotax 2 stroke Repair Manual states in regards to lubricating the exhaust ball joints - https://www.rotax-owner.com/en/support-topmenu/engine-manuals#2-stroke-historical-documents

With that said, the type of kit you have installed removes these "Ball Joints" and allows for a more secure system that doesn't move or "bind" therefore removes the need for lubrication. Even with the "Ball Joints" the breaking of the exhaust system has not been a major issue when they lack lubrication. A bigger concern is the breaking and deterioration of internal baffling of the muffler and welding of cracks... External cracking on the muffler is an indication of internal issues within the exhaust system that should not be ignored. Here is a flight safety article we wrote on the topic https://www.rotax-owner.com/en/flightsafety/651-ai-exhaust-safety.

Thank you said by: Dennis Urban

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Maintenance schedule, ball joints, ball joint conversion kit

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