Question about 2003 ATK 500

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Some sites seem to indicate that the Rotax 500's have 5 speeds and other sites say 6 speeds? Do you know?

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Hi, Scottemil for this situation I would call my local dealer or reputable shop's service/parts department and inquire about any possible quick fix or parts inquiry. If necessary transport your vehicle to the dealer or shop and have a professional technician take it for a test drive, if it is in running condition, and give you a written estimate of repairs and answer any specific questions you may have about your issue. For more information about your issue please visit the website below. Good luck and have a nice day.
http://www.atkusa.com/parts/parts

Btw, I’m available to help over the phone in case u need at https://www.6ya.com/expert/gregg_c0ec1df182c7330e

Posted on Oct 31, 2015

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Posted on Jan 02, 2017

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1 Answer

My Grand Touring Rotax 500 won't start. Plugs have spark but get soaked every time I try to start.


You have a build up of fuel in the crank case. turn the fuel off and crank the engine over til it starts. While running turn the fuel back on.Also make sure your choke cables arent out of adjustment.

Feb 25, 2015 | Winter Sports

1 Answer

Spark plug gap for 503 Rotex


Hi Faye,

I found this,





Rotax spark plug advisory for ultralight, experimental lightsport, amateur built aircraft.




Rotax 2 stroke aircraft engine spark plugsThe recommended spark plugs for the Rotax 277, Rotax 377, Rotax 447, Rotax 503, Rotax 532, Rotax 582 are the NGK B8ES series or the NGK BR8ES ( the R in the spark plug denotes it is a resistor plug and should be used in all of the CDI ignition engines.



BUT the Bosch points ignition engines should NOT use both a resistor plug and a resistor spark plug cap - use one or the other.

The least expensive option in the long run is the cap as you purchase it once while the resistor plugs cost more than the standard plug each time you buy them.



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Use spark plugs that have a SOLID TIP - DO NOT USE spark plugs that have an aluminum screw on tip. They vibrate loose, the tip wears making a loose cap to plug fit, and can lead to the spark plug arcking across from the cap to the plug. Also the screw on style spark plugs are NOT designed for our applications, the gap is generally set up for .030 to .035 thou. The solid tip spark plugs are set up for a gap of .015 to .020 thou.

Spark plug gap



  • Allowable range: 0.4-0.5mm / .015 -.020"


  • Optimal: I usually set them to .015 and let them wear out to .019


  • This also helps getting the engine started in colder conditions


This was found at

Oct 10, 2014 | Cars & Trucks

1 Answer

Hi, Fitted new clutch plates on my sons aprilia rs125 rotax 123 engine. Can you adise do i tighten the springs down untill they stop ? Is definitely 6 friction 6 plain plates, which order do they go...


Hi, Joemoturner I am sorry you can't find the first and best tool you ever bought for your Aprilia but despair not for a mere $10 you can download another one. For more information about your issue, please visit the websites below. Good luck and have a nice day.
https://www.tradebit.com/filesharing.php/search/0/1997+aprilia+rs+125+rotax

Btw, I’m available to help over the phone in case u need at https://www.6ya.com/expert/gregg_c0ec1df182c7330e

Jun 15, 2011 | 1997 Aprilia RS 125 Extrema

1 Answer

Bike cut out like it had just run out of fuel,cleaned carb but still won't fire up have got spark


Hi, Neilburne the following applies to carbureted also fuel injected models and the usual suspects are:
1. Severely discharged or damaged battery, 9 volts or lower.
2. Failed alternator/generator and or voltage regulator.
3. Loose or corroded battery terminals and or cables especially the "NEGATIVE" cable, look for loose, corroded, or broken connectors inside the cable harness at "BOTH" ends.
4. Failed main circuit breaker or ignition switch, check for loose connections and continuity.
5. Failed system and or ignition relay, check for continuity.
6. Failed ignition coil, ignition/electronic module.
7. Failed CKP, CPS, CMP, MAP, TPS, or BAS sensor, corroded, loose or broken wire connector pins/sockets.
8. Throttle cables and or idle speed improperly adjusted hot idle speed should be 950 RPM to 1000 RPM.
9. Air/fuel mixture screw improperly adjusted.
10. Water or dirt in the fuel system, carburetor or filter.
11. Restricted, blocked or kinked fuel line.
12. Fuel tank empty.
13. Gas cap is not venting properly or fuel tank venting system blocked.
14. A failed fuel pump, pressure regulator and or fuel injectors.
15. Vacuum line from intake manifold to petcock broken, cracked, or not attached, carburetor vent line plugged.
16. Needle and seat stuck closed in the float bowl.
For more information about your issue and free downloads that you need please visit the websites below. Good luck and have a nice day.
ccm 604e dual sport rotax opinions
CCM 604 Trail 2001 service manual DOWNLOAD FREE FULLMANUALS COM
Rotax Manual pdf
CCM Spares 604 Supermoto
CCM 604 DS Dual Sport

Btw, I’m available to help over the phone in case u need at https://www.6ya.com/expert/gregg_c0ec1df182c7330e

Jan 09, 2011 | 2001 CCM 604 DS Supermoto

1 Answer

I need are the head bolt torque specs for a 1982 Rotax 503 fan cooled engine. This engine will be used in a "go-cart". One dealer told me to change the carb jets 4 sizes smaller than the factory ones for...


Jet size varies depending on modifications and air density. We use a Mychron w/head temp gauge to keep an eye on our kart jetting on a Honda Clone. There are probably some sites out there with forums that deal with Rotax on karts. They may can help. Four jet sizes seems a big leap to me on a guess but then again I've never dealt w/Rotax.
Check out this site for all the torque specs -

http://www.ultralightnews.ca/articles/torque.htm

Jan 08, 2018 | Sport & Outdoor - Others

2 Answers

I have a 1991 rotax ATK 406 dirt bike and won't run right


try cleaning the fuel filter, it may be as simple as that

Jul 12, 2010 | ATK 125 2-stroke Motorcycles

1 Answer

Electrics has gone,not ticking over once started


Hi, Ali_I_simpso and the usual suspects are:
1. Idle speed improperly adjusted.
2. Inlet system air leak.
3. Leaking accelerator pump.
4. Loose low-speed jet.
5. Plugged low-speed jet.
6. Contaminated or plugged low-speed circuit.
7. Enrichner valve is not seated or leaking.
For more information about your issue and free downloads that you will need please visit the websites below. Good luck and have nice a day.
no tickover on 604 sm
Wont run 604 rotax
CCM 604 Trail 2001 service manual DOWNLOAD FREE FULLMANUALS COM CCM Spares 404 Enduro
CCM 604 DS Dual Sport

Btw, I’m available to help over the phone in case u need at https://www.6ya.com/expert/gregg_c0ec1df182c7330e

Jun 20, 2010 | 2003 CCM 604 DS Dual Sport

1 Answer

Temperature indicator turns on in my Epson EMP-500


it appears that one of the cooling fans in ur projector is jammed or not spinning at the required speed!
ope the projector & observe the fans as u switch on!!!if the fans seem fine, then it could be a defective thermistor!

Feb 06, 2009 | Epson EMP 500 Multimedia Projector

1 Answer

Drill slowing down under load


indicates either field windings or armature problem
at 12 years parts will be hard to come by

Jan 23, 2018 | Makita HP2010N 3/4 Hammer Drill, 6 AMP,...

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