SERVICE INSTRUCTION

SELECTION OF SUITABLE OPERATING FLUIDS

FOR ROTAX® 2-STROKE UL ENGINES
SI-2ST-008
Repeating symbols:
Please, pay attention to the following symbols throughout this document emphasizing particular information.
▲ WARNING: Identifies an instruction, which if not followed, may cause serious injury or even death.
■ CAUTION: Denotes an instruction which if not followed, may severely damage the engine or could lead to sus-
pension of warranty.
◆ NOTE: Information useful for better handling.

A revision bar outside of the page margin indicates a change to text or graphic.
1) Planning information
1.1) Engines affected
All 2 stroke UL engines
1.2) Concurrent ASB/SB/SI and SL
none
1.3) Reason
Field experience has shown that additional information about the choice of suitable operating fluids, such as
2-stroke oil, gearbox oil, coolant and fuel for ROTAX 2-stroke engines is necessary.
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1.4) Subject
Selection of suitable operating fluids for ROTAX 2-stroke UL engines.
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This information should help the aircraft manufacturer and operator to ensure that the operating conditions
and installation are correct and thereby achieve optimum performance and reliability.
1.5) Compliance
According to the Maintenance Manual of 2-stroke engines current issue.
▲ WARNING: Non-compliance with these instructions could result in engine damages, personal injuries
or death.
1.6) Approval
The technical content is approved under the authority of DOA No. EASA.21J.048.
1.7) References
In addition to this technical information refer to current issue of
- Operators Manual (OM)
- Maintenance Manual (MM)
- Installation Manual (IM)
◆ NOTE: The status of Manuals can be determined by checking the table of amendments of the Manual.
The 1 column of this table is the revision status. Compare this number to that listed on the ROTAX
st
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WebSite: www.rotax-aircraft-engines.com. Updates and current revisions can be downloaded for

free.
d04362.fm

April 08th 2009 Current valid documentation see: SI-2ST-008

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 1.8) Other publications affected
This Service Instruction (SI) will substitute the following:
- SI-13-1994 „Using auto fuel in ROTAX two cycle aircraft engine“.
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2) Material Information
2.1) Material - cost and availability
None
3) Lubricants
3.1) Engine lubrication
When the oil in 2-stroke engines is mixed into the fuel system, then the oil and its corrosion protective ingre-
dients are continuously burned and then replaced by new fuel-oil-mixture. The oil is therefore exposed to the
moving parts only for a short time before it is consumed up. Therefore it is important to use oils of high qual-
ity, to ensure that the engine gets the necessary corrosion protection and lubrication.

▲ WARNING: If the engine has no oil injection, then in accordance with the operators manual it is nec-
essary to add to the fuel 2% Super 2-stroke oil (50:1).

Criteria for the selection of 2-stroke oil:

- Super 2-stroke engine oil ASTM/CEC standard classification API-TC
- The pour point of the oil must at least be 10 °C (18 °F) below the ambient temperature.

◆ NOTE: Oils that are intended for marine (watercooled) 2-stroke engines are not suitable for use
in UL-engines due to their low operating temperatures. Oils formulated for air cooled en-
gines are recommended due to their high temperature properties.

brand description

CASTROL® Active 2T

CASTROL® Valvoline Syn Power 2T

SHELL® AeroShell Sport Plus 2

SHELL® Advance Ultra 2T

SHELL® Advance S 2

SHELL® Advance VSX 2

SHELL® Advance Scooter 2

TEBOIL® 2T MIX

YACCO® MVX 500 2T+MVX 1000 2T

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 3.2) Lubrication at the rotary valve drive
The lubricant for the rotary valve drive is the same as used for engine lubrication. See section 3.1. The oil
should not be diluted.
3.3) Propeller Gearbox
Lubrication takes place with separate oil in the gearbox.
Special oils have to be used in the propeller gearbox. The main task of the gear box lubricating oil is the
transmission of force and pressure, the diminishing of friction and abraison, the transfer of lost heat, protec-
tion from corrosion and absorbing particles from wear.

Criteria for the selection:

- Oil for gearbox according to API-GL5 or GL6
- Viscosity SAE 140EP or 85W-140EP

brand description

CASTROL® EPX 85W/140 Manual

GEARTEX® EP-C 85W/140

SHELL® SPIRAX A 85W/140

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4) Coolant
4.1) General
The 2-stroke engines of the type 462 UL, 532 UL, 582 UL and 618 UL have liquid cooled cylinder heads and
cylinders. The coolant transfers away heat from cylinder heads and cylinder to avoid overheating. Using the
correct coolant can avoid corrosion of parts and freezing of the coolant.
4.2) Mixing ratio antifreeze / water
50% antifreeze with anticorrosive and 50% pure (distilled) water, or an equivalent premixed coolant.
■ CAUTION: The coolant has to be used as stated in the manufacturers descripton.

The ratio antifreeze/water should not exceed any constraints given by the coolant manufacturer. Mixing ratio
exceeding the limits stated by the manufactuerer may result in thixotropy (jelling) of the antifreeze which se-
riously lowers the coolant systems efficiency.

■ CAUTION: Thixotropy of the coolant can be harmful for components of the cooling system and can
influence the cooling circuit to and from the expansion tank.
◆ NOTE: Coolant should be a low silicate or silicate free formular. Follow coolant manufacturer di-
rections regarding mixture percentages etc.

brand description

BASF® Glysantin Protect Plus/G48

CASTROL® Antifreeze All-Climate

CASTROL® Antifreeze Anti-Boil

PETROL® Antifreeze Concentrate / Antifreeze G 11

SHELL® Antifreeze Concentrate

SHELL® DEX-COOL

TEXACO® Havoline Extended Life Antifreeze / Coolant

DEX-COOL

VELVANA® FRIDEX G48

YACCO® LR-35

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5) Fuel
For ROTAX aircraft engines different fuel types are available. See Operators Manual of the relevant engine type
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and/or the table in chapter 5.3.

5.1) Automotive fuels
In addition to AVGAS various automotive fuel types with different quality are available. Due to various envi-
ronmental, economic and political reasons a number of fuel types with different amount of ethanol blend is
available. Therefore the maximum amount of ethanol blend is defined as follows:
5.1.1) E10 (Unleaded gasoline blended with 10% ethanol)
In addition to AVGAS and unleaded automotive fuel (Mogas) the ROTAX engine type 503 UL and
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582 UL are now approved for use with E10. At an ethanol amount of maximum 10%, higher exhaust
gas temperatures (EGT) may be possible. If the maximum allowable EGT is exceeded, consult an
authorized maintenance facility for relevant checks and for further corrective actions (e.g. other car-
buretor jetting).
◆ NOTE: All other ROTAX 2-stroke UL aircraft engines as e.g. 447 UL, 618 UL etc. were not
tested for E10 and are not approved for it. Even if there is no negative feedback
from field information, these engine types should only be operated with fuels with
max. 5% alcohol.
Fuels that contain more than 10% ethanol blend have not been tested nor are they permitted for use.
5.1.2) Suitability of fuel system components of airframe
ROTAX urges owners to confirm with there airframe manufacturer that ethanol blended fuels of up
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to 10% (E10) are compatible with all fuel systems components.

It is the responsibility of the aircraft manufacture to test their fuel system components and supply any
further information on techniques, procedures and limitations of using ethanol blended fuel.
ROTAX recommend that aircraft manufactures and owner/operators read the following:
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- FAA Advisory Circular Letter AC 23.1521-2

- FAA Special Airworthiness Information Bulletin CE-07-06
- EASA Safety Information Bulletin - SIB 2009-02
These contain details regarding the use of ethanol (alcohol) blended fuels and the type certificate
requirements.
It is strongly recommended that non certified aircraft also conform to the information given in the
above documents.

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 5.2) Fuel according to local standards
The following fuels can be used.

MOGAS description

EN 228 Normal 1)

European norm EN 228 Super 2)

EN 228 Super plus 2)

Canadian norm CAN/CGSB-3.5 quality 1 3)

US norm ASTM D4814 3)

AVGAS description

Aviation standard AVGAS 100 LL (ASTM D910)

■ CAUTION: Engines of type 618 UL require at least RON 95 (AKI 91)

1) at least RON 90
2) at least RON 95
3) at least AKI* 87

* Anti Knock Index, (RON+MON)/2

■ CAUTION: Use only the correct fuel for the specific climate zones.
◆ NOTE: There is a risk of vapor lock formation if winter fuel is used for summer operation.

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6) General engine operation requirements and operating limits
1. Regular synchronization of bowden cable for throttle and choke adjustment can greatly improve the smoothness
of engine operation.
2. Proper adjustment of the engine idle speed and maintenance of the air induction system can support smooth
engine operation and helps to maintain the correct air / fuel mixture. Proper air / fuel mixture will reduce the sep-
aration of the non - volatile components e.g. in leaded AVGAS, and helps to minimize the rate of deposits in the
engine.
3. Avoid rapid changes in engine RPM immediately after start up (not more than 3000 rpm).
4. Rapid engine cooling down resulting from rapid altitude changes, landing manouvers flown at low power set-
tings, or rapid shut down after landing or ground operations should be avoided.
5. Correct balancing of the propeller to a tolerated value can greatly reduce vibration, decrease wear of engine and
gear reduction unit components, improve engine performance, and add to engine life. Modern electronic propel-
ler balancing equipment allows quick dynamic balancing of propellers without removing the propeller from the
aircraft. Other benefits of correct propeller balance include the reduction of cockpit noise and vibration levels,
and a reduction in fatigue of exhaust components, air boxes, sheet metal components, cowlings, engine linkages
and aircraft sections.
7) Summary
▲ WARNING: Non-compliance with these recommendations could result in engine damage, personal injury or
death !

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