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MXZ 583 ROTAX CSI
http://www.pilotodyssey.com/PO/viewtopic.php?f=24&t=3108		 Page 1 of 1
Author:  hoser [ Sun May 27, 2007 9:00 pm ]
Post subject:  MXZ 583 ROTAX CSI
I always like to tear down the Engine for inspection ASAP on any toy I buy especially one with a 2 stroke Engine , we all know they run perfect right up until the last millisecond then poofkaboom.

One thing I noticed with the MXZ when I picked it up was it smoked alot, the owner claim it was from fogging it after the snow season, sounds reasonable I did run it long enough to clean out but I also noticed the exhaust had a huge amount of oil dripping out, the exhaust at the exhaust manifold also was leaking and dripping oil into the bottom of the Engine compartment.

Once out I pulled the intake manifold and rotary valve, I noticed a bunch of oil in the pocket where the drive gear is for the oil injection way to much to be considered normal so I filled up the RV drive gear lube hose to see if the RV drive shaft seal was leaking, it turns out it was where the 2 cases meet it was leaking, see the pics.

I will know more when I split the cases, I planned on changing the crank seals so this is not a big deal it was coming apart anyways.

The green arrows are pointing to damage to the cases where metal got between the rotary valve (RV) and the case the red arrows are where the cases meet and the oil is seeping out between the cases.

Attachments:
RV leak.jpg
RV leak.jpg [ 106.43 KiB | Viewed 9330 times ]
Author:  hoser [ Sun May 27, 2007 9:03 pm ]
Post subject: 
After 10 minutes the oil puddles up.

Attachments:
RV leak1.jpg
RV leak1.jpg [ 85.22 KiB | Viewed 9328 times ]
Author:  hoser [ Sun May 27, 2007 9:06 pm ]
Post subject: 
RV damage by something hard, assuming metal getting between the RV and the cases.

Attachments:
RV damage.jpg
RV damage.jpg [ 68.98 KiB | Viewed 9327 times ]
Author:  hoser [ Sun May 27, 2007 9:06 pm ]
Post subject: 
Same damage spot just the other side of the RV

Attachments:
RV damage1.jpg
RV damage1.jpg [ 82.2 KiB | Viewed 9326 times ]
Author:  hoser [ Sun May 27, 2007 9:11 pm ]
Post subject: 
The casting flaws on this intake setup match up alike a after thought product, they don't match, this will change, the pink arrows are the cases their is a ledge on the sides, you can only remove so much metal on the sides then yo u lose critical support the RV needs to back it up, the factory could have done a better job of designing the intake, I will use epoxy to fill the area between the blue arrows on the manifold to build it up then match them to the cases.

Attachments:
bad match.jpg
bad match.jpg [ 49.57 KiB | Viewed 9325 times ]
Author:  hoser [ Sun May 27, 2007 9:11 pm ]
Post subject: 
Both sides are the same.

Attachments:
bad match1.jpg
bad match1.jpg [ 43.94 KiB | Viewed 9324 times ]
Author:  hoser [ Sun May 27, 2007 9:15 pm ]
Post subject: 
More pics of intake flaws and tunnel problems that need changed, this will really wake up this Engine once the casting and production flaws are removed.

Attachments:
tunnel flaws1.jpg
tunnel flaws1.jpg [ 68.22 KiB | Viewed 9322 times ]
tunnel flaws3.jpg
tunnel flaws3.jpg [ 43.94 KiB | Viewed 9322 times ]
tunnel flaws4.jpg
tunnel flaws4.jpg [ 66.33 KiB | Viewed 9322 times ]
tunnel flaws.jpg
tunnel flaws.jpg [ 69.97 KiB | Viewed 9322 times ]
Author:  hoser [ Sun May 27, 2007 9:19 pm ]
Post subject: 
The cylinder on the clutch side had the metal that hit the RV damage the piston and cylinder wall slightly.

Attachments:
no bevel damage.jpg
no bevel damage.jpg [ 63.82 KiB | Viewed 9320 times ]
Author:  hoser [ Sun May 27, 2007 9:20 pm ]
Post subject: 
No bevel around the ports.

Attachments:
no bevel.jpg
no bevel.jpg [ 55.13 KiB | Viewed 9319 times ]
no bevel1.jpg
no bevel1.jpg [ 52 KiB | Viewed 9319 times ]
Author:  hoser [ Sun May 27, 2007 9:30 pm ]
Post subject: 
RAVE valve, this is cool, at lower RPM's the valve is lowered effectivally lowering the height of the exhaust port, this means a longer power stroke, more trapped charge so more compression, this makes lots of bottom end torwque, at higher RPM's the valve will raise changing the port timing, mo power at higher RPM's

Attachments:
RAVE valve.jpg
RAVE valve.jpg [ 63.78 KiB | Viewed 9318 times ]
Author:  hoser [ Sun May 27, 2007 9:33 pm ]
Post subject: 
I made some port molds of one of the cylinders to see how much work they need like most production machines they need dialed in.

Attachments:
DSC00444.JPG
DSC00444.JPG [ 134.26 KiB | Viewed 9317 times ]
DSC00447.JPG
DSC00447.JPG [ 139.91 KiB | Viewed 9317 times ]
DSC00448.JPG
DSC00448.JPG [ 139.71 KiB | Viewed 9317 times ]
Dsc00449.jpg
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DSC00450.JPG
DSC00450.JPG [ 140.59 KiB | Viewed 9317 times ]
Author:  hoser [ Sun May 27, 2007 9:34 pm ]
Post subject: 
More

Attachments:
DSC00453.JPG
DSC00453.JPG [ 139.39 KiB | Viewed 9316 times ]
DSC00454.JPG
DSC00454.JPG [ 139.11 KiB | Viewed 9316 times ]
DSC00456.JPG
DSC00456.JPG [ 142.17 KiB | Viewed 9316 times ]
Dsc00457.jpg
Dsc00457.jpg [ 43.43 KiB | Viewed 9316 times ]
Author:  hoser [ Sun May 27, 2007 9:35 pm ]
Post subject: 
Some serious deformity or flat spots here.

Attachments:
Dsc00458.jpg
Dsc00458.jpg [ 49.5 KiB | Viewed 9290 times ]
Author:  hoser [ Sun May 27, 2007 9:48 pm ]
Post subject: 
The matching I will be doing is about the same as I did to the 440 ZOOM ZOOM
http://pilotodyssey.com/PO/viewtopic.php?t=759


:shock:
Author:  hoser [ Thu Jun 07, 2007 2:49 am ]
Post subject: 
Here are some more pics of the factory casting flaws.

Attachments:
skidoo flaws.jpg
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skidoo flaws1.jpg
skidoo flaws1.jpg [ 38.47 KiB | Viewed 9177 times ]
skidoo flaws2.jpg
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skidoo flaws3.jpg
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skidoo flaws4.jpg
skidoo flaws4.jpg [ 54.11 KiB | Viewed 9177 times ]
skidoo flaws5.jpg
skidoo flaws5.jpg [ 62.31 KiB | Viewed 9177 times ]
skidoo flaws6.jpg
skidoo flaws6.jpg [ 75.08 KiB | Viewed 9177 times ]
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