Question: What does it cost to service, or rebuild a Rotax 503?
Answer: The simple answer is: Labor plus parts. As you can see below, the biggest variable is parts. Based on Green Sky's twenty years experience with Rotax UL series engines, our opinion is: the random replacement of parts, without considering condition, is not mechanically or economically justified. Consequently, we service engines the hard way, inspecting, measuring, grading, and documenting

Your attention to careful packaging will pay off in spades. Check HERE on how to pack your engine.

When you click on an item, it will be posted to a shopping cart where the quantity can be entered or changed as desired. Simply close the shopping cart window to return to this page to add each successive part or service. If you experience problems, check out the HELP section first. If you don't find a solution there, please email, jerry@greenskyadventures.com  or call.

Parts are genuine Rotax UL series replacement parts unless otherwise noted
Price and availability are subject to change without notice

Part No	Description	Price
TD2	Rebuild Service, Rotax 503dcdi UL	$320.00	Add to Estimate
PDC503	Powder Coat Service for 503 at rebuild	$175.00	Add to Estimate
996 441	Crankshaft Assy, Factory New ...complete with rod, main, and wrist pin bearings.  Please Note: This is an Exchange price requiring a special crankshaft replacement form (CRPF) which Green Sky will process for you when we perform your rebuild.  This is a replacement item at 300 hours on the Rotax Maintenance Plan. Field experience indicates the 447 and 503 cranks can be replaced "on condition"	$845.26	Add to Estimate
994 236	503 8-bolt Engine Gasket Set 100% replacement item at major service	$145.59	Add to Estimate
980 511	Fan Belt, 503 Replace "On Condition"	$25.44
832 161	Fan Bearings Replace "On Condition"	$30.70 ea
996 245	Piston Assembly, Standard. Includes rings. Does not include Wrist Pin or Circlips We generally replace piston assemblies "on condition" Piston to Cylinder clearance and ring gaps are determining factors. If a piston is past 50% of it's wear range but the rings are worn excessively, it does not make economic or mechanical sense to replace only the rings, because they constitute nearly half the price of a new piston assembly complete with rings.  Replace "On Condition"	$172.15 ea
BORE	Cylinder Boring, per hole The 503 cylinders can be bored two oversizes, +.25mm and +.50mm. Generally, a cylinder will not require boring when pistons are replaced for the first time on a particular bore size. Most of the wear occurs on the piston. For instance, with a standard size bore, let's say an engine with 600 hours has piston or ring clearances near "wear out" point. ...Replacing the pistons with new, standard size will most likely bring clearances back very close to new specs.  Even with seizures, a cylinder can usually be repaired without going to the next bore size. Severe trauma, like broken rings, foreign object ingestion, etc. most likely result in boring,	$45.00 per hole	Add to Estimate
996 246	Piston Assembly, 1st oversize, 503	$182.39 ea
996 247	Piston Assembly, 2nd oversize, 503	$182.39 ea
916 186	Wrist Pin, 503, 532, 277these also, can be replaced "on condition" Their wear is not predictable. Replace "On Condition"	$41.55 ea
915 850	Rectangular ring standard 503, 532, 277 Replace "On Condition"	$45.42 ea
915 851	Rectangular ring 1st over 503, 532, 277 Replace "On Condition"	$47.69 ea	Add to Estimate
915 852	Rectangular ring 2nd over 503, 532, 277 Replace "On Condition"	$47.69 ea	Add to Estimate
215 235	Semitrapezoidal ring standard 503, 532, 277 Replace "On Condition"	$69.45 ea
215 236	Semitrapezoidal ring 1st over 503, 532, 277 Replace "On Condition"	$73.82 ea
215 237	Semitrapezoidal ring 2nd over 503, 532, 277 Replace "On Condition"	$73.82 ea
832 320	Cageless Wrist Pin Bearing These come as part of the replacement crankshaft exchange package. Replacement is rarely required prior to crankshaft replacement	$46.65	Add to Estimate
866 705	Sparkplug Protector These burgundy colored OEM caps have 5k ohm resistance. We check the R values as a matter of routine during major service. Occasionally we find open resistors. BTW, we apply Silicone Dielectric Compound to all electrical connections serviced. Replace "On Condition"	$22.55	Add to Estimate
866 705A	Sparkplug Protector These BLACK colored OEM caps have 5k ohm resistance. These are identical to the caps above, in every respect, except color and price Replace "On Condition"	$4.95	Add to Estimate
Accessories	Gearboxes
GCCM	Gearbox Service, Type C, Complete gearbox is disassembled, inspected, and updated or repaired as required	$75.00 + parts	Add to Estimate
995 775	Gasket Set for Type C Gearbox 100% replacement item at major service	$82.89	Add to Estimate
GECM	Gearbox Service, Type E, Complete gearbox is disassembled, inspected, and updated or repaired as required	$95.00 + parts	Add to Estimate
995 776	Gasket Set for Type E 100% replacement item at major service	$84.57	Add to Estimate
GBCM	Gearbox Service, Type B, Complete gearbox is disassembled, inspected, and updated or repaired as required	$55.00 + parts	Add to Estimate
995 781	Gasket Set for Type B 100% replacement item at major service	$49.55	Add to Estimate
PDCGBX	Powder Coat Service for Gearbox at service	$45.00	Add to Estimate