Yamaha Phazer Engine Airplane Conversion

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Yamaha Phazer engine conversion for aircraft use. Kolb Firestar 2 with a rotax 503 being replaced with an engine from a yamaha phazer snowmobile
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[@montanasoftware5954]

Thank you for paving the way on this ... doing the hard work of developing the gearbox adapter, prop testing, etc. This is a big service to Experimental Aviation. 🙂

[@danclark5243]

Absolutely the most realistic approach of a 4 stroke. Will be following !

[@nancykarolak5802]

Ben, I’m so proud of you. You have been accomplishing so many things. It seems like just a short time ago when I took that picture of you and your dad with his hang glider. Love, Mom

[@cwakamatsu]

I believe this engine is the perfect engine for this application. You don't just get fuel injected 4 stroke reliability... You get Yamaha snowmobile, high RPM, tougher than nails proven reliability! I wished Yamaha would allow someone to acquire brand new engines and create a ready to install package! It would be hands down the best in the market. In my opinion.

[@rochboulanger6565]

I’ve owned Yamaha snowmobiles and motorcycles. Although I still love them, I think people should stop making them out to be « more bulletproof » than others. I towed 3 Yamaha’s off the snowmobile trail last winter (using my 2 stroke Polaris which has never had an issue). I know my own personal experience doesn’t prove anything…but Im thinking a « higher revving » engine might not always be a good thing. 🤷‍♂️

[@G_Money72]

I think four strokes could single handily revive ultralights. SUB’d

[@martinodendaal9267]

Great work ! I'm excited to see the results !

[@davidrobins4025]

Exciting days ahead. Good progress on the conversion.

[@mibear100]

Great job Ben! You have a great adventure going on there👍

[@OleTrapper69]

I’ve always wondered why engines on dirt bikes aren’t utilized for things like this. For example I have a fuel injected 4 stroke 450. Super reliable and light weight. Awesome channel !

[@prof.heinous191]

Great pioneering project - this needs to happen - all sorts of 582 (etc) pusher folk will follow with interest!

[@thomasparkhurst2848]

Hi Ben, I'm a firestar flyer that's leaning toward an engine upgrade from the existing Rotax 503 that's on it now. This phazer has potential to be an excellent match. In addition to upgrading the power I'm planning to reduce the wing span by at least 4 feet which would make it somewhat of a Slingshot clone without the jumpseat.

[@kevinsavas7173]

Awesone! Thanks for videoing this swap. I'm really interested in the final weight.

[@bkairys]

Soon very soon we will have numbers

[@georgestone1282]

Looks like you have a fun project to complete. I have a kitfox as well with the 582 , does a good job but could use a little more. I will be following your progress. Goo job!

[@Stromzilla]

Can you imagine adding a turbo like they’re doing on the Apex engine for some short term boost? You are doing some really cool stuff. I have zero interest in running 2-strokes but the work I’ve been seeing with the Apex and now your Phazer motor really has my interest...love it!!!

[@MACE1-1]

I am very excited to see the younger generation finally figure out how to do something like this....Itsbeen a long time coming....!

[@michaelguy7168]

Really interested in this conversion, I converted a BMW Motorcycle engine 20 years ago on a Kitfox2. Looking for another light aircraft and this looks like a great option. Can’t wait to see your progress.

[@randyberry7737]

I owned a Kolb Firestar some years back and had a new Rotax 503 engine quit on me in flight after only 70 hours in service. As they say "It's not IF a 2-stroke will quit on you, it's WHEN" I made an emergency landing between hay bales and everything came out fine, but it really put me off of 2-cycle engines. Also, Rotax is not making the 377, 447 or 503 engines anymore and about to stop making the 582, so they are getting scarce and expensive. I''ve always considered the 2-stroke engines to be the "bugaboo" and least dependable part of most ultralight and small planes. The Rotax 912 is definitely prohibitively expensive and too heavy for many smaller aircraft, so I'm happy to see that someone is making progress on a different 4-cycle engine conversion for small aircraft. Keep up the good work!

[@DLStarbuck]

Why did your 503 quit?

[@randyberry7737]

Bec@@DLStarbuck Because of carbon build up behind the piston rings which causes the rings to expand and causes the engine to stop in a few seconds in my case but sometimes suddenly. Then, you can usually start it up again once it cools down some but if you try to fly again, it will happen again. I hung the engine upside down and soaked each piston and rings in a gallon of carburetor cleaner and scraped the carbon out of the ring grooves with a piece of broken ring. A lot has to do with the oil you use. Never had a problem with AV-2 oil but I had switched over to Pennzoil 2-cycle air cooled oil because one little yellow bottle mixes well with 6 gallons of gas at 50:1 ratio, but never again.

[@politicalsheepdog]

Huge improvement over the Rotax.

[@davebourdon3258]

Thanks for your videos. I am getting ready to put together a Avid Flyer B model. It needs an engine.

[@tinolino58]

Very inspiring!

[@danielrohe4304]

I like your thinking. Great for the Rukus UL good luck with it. I would have gone thicker with the gearbox mounting plate depending on the alloy. Marine grade 586 would be my choice after building a center consul skiff out of it.

[@johntempest267]

Love what your doing. I have a Firestar 1 w 447. I dream of going 4 stroke one day. I would be concerned about cruise rpm. My Rotax (as you know) climbs out at 6250 rpm and cruises at 4500 to 5500, your looking at those engine speeds in the rear view mirror! Lol IDK if the Yamaha is "stressing" maintaining 7500 rpm over a long time, but I would be. Good luck with your Kitfox project, and thanks for posting.

[@patrickmckowen2999]

Excellent 👍

[@KevinArmstrong4154]

You might know Charles Kizer, he built one using the three cylinder Yamaha, I'm flight testing the V-Twin 800cc out of a Hisun ATV, sorting the fuel injection has been interesting.

[@KGFlyer55]

Awesome, loving the new content 👌

[@jasonomelchuck906]

I have converted and installed a Yamaha Vector (3cyl) on a Kolb MKIII. There is a video on KZbin. I believe you will need a clutch or some type of decompression device to get the engine to start. I think there have been some projects before you and they discovered that the exhaust is critical. Since you have the space, you may want to run the exhaust down into the cage area into a long secondary and try to mimic the snowmobile exhaust best you can. Good luck, be safe and keep us updated.

[@bkairys]

Hi Jason, I have seen your video. Looks nice! I have seen phazers on test stand with no clutch that seem to start ok. There is a clutch that would work for a c box if need be. My exhaust will be the exact length as the stock system, I did keep that in mind. Whats the performance of the vector like? Any reason to choose that over the more powerful apex that is basically the same weight?

[@Flexwingflyer1]

Really love what you have done here.Thank you very much for sharing. I am going to go down this road myself for a swap into a Skyranger. I would ask what gear ratio you are using and size of your prop? Thanks again

[@davidallen9526]

I really like your project so far. Do you have mechanical drawings for everything your doing? I have a Flightstar 2SL with a 503 duel carb and a C box. I've been looking into moving to a four stroke like HKS and a few others. I'm interested in this project. Please keep us informed on the progress. Looking good so far buddy. Blue skies and tailwinds.

[@flytoday]

subbed!

[@johngilory3446]

Good

[@ronstiles2681]

Nice work but I would feel better if it had a second ignition for backup, have fun and be safe

[@darylbuckner5596]

Ben your the man! 🤙 Any chance you have the engine mount schismatics or for sale?

[@jrbailey3208]

Hail and Good Morrow, Thanks for this VERY interesting update! Your train of thought, reasoning, and overall platform paradigm is a breath of fresh air for the Ultralight/ELSA classes! I DESPISE two-stroke with a passion usually only reserved for Le Pues (skunks) and indoors arachnids (outdoors, they're ok)! Noisy, smelly, pain in the seat to fuel, dirty to operate, and their TBO's scream pure insanity for what they cost to originally buy and then Overhaul! I'm still earthbound (financially I'm in serious straights, just trying to keep the utilities on so me, the cats, and the quail do not freeze, have water, and ability to cook the food from the food bank!), but plan to 'trade my way' to a Part 103 sooner, rather than later! However, 4 stroke is my ONLY choice, I will NOT compromise for a crappy 2 stroke platform! What I see in your video is NOT just a quality working paradigm for your Firestar (oh how I wish it had aluminum wings rather than fabric; whenever I can afford to do it, I'll be choosing a used Titan II-hopefully an SS model, because of the aluminum wings), but a Thriving Design for your New Business! No foolin, if that hack Honda Used Car salesman can make a go of selling used Honda engines for higher end ELSA's, YOU can do the same thing (except with integrity) for everyone flying a Beaver, Chinook, Kolb models, first 3 or 4 Kitfox series, and the dozens of other planes in those categories! You've got the shop tools for it (walking before running, financially speaking), you've got the skill sets, you've got the patience, and best of all, you've got the determination to stay EMPIRICALLY FOCUSED on real world performance numbers for the Phaser Conversion! You and I both KNOW there is a THRIVING MARKET that already exists 'out there' for affordable 4 stroke replacements for the 500 series two stroke engines: how many times have you had conversations, or heard conversations, of people just fit to be tied about all the 'negatives' (pain in the but realities) of flying 2 stroke engines? The reliability of 4 stroke is key, which is directly related to the EASE of owning and operating a 4 stroke when it comes to maintainence. It starts right where you're at in your Build Process; step by step, hard core reliable data for performance, operational numbers, as they directly relate to consistency for those numbers! One of the key aspects for choosing a Yama-hammer engine is parts costs, availability, and ease of replacement (especially for consumables). Anywho, after watching your presentation, all I could keep thinking is: "He's got a gold mine on that table. He just needs to keep going." Lastly, the ONLY negative I had about your video was the opening on that One Wheeled Monstrosity; never did like skateboard, always preferred two wheels to one! Personal bias of course.....oh yes, and the Red Bull.......there's a LOT better drinks out there than that; yes, personal bias once again...... Cheers from the Oil Patch in Central WY

[@bkairys]

Thanks for the informative replies. Will consider that!

[@rubenvor]

Man! Awesome work! How do you get rid of the motorcycle transmission?

[@jesseperez7253]

Wow you got redbull to sponsor you? Good for you Sr.

[@justajoe8466]

Question is the engine internally balanced or does it use the fly wheel to balance externally? Could be a time bomb for the bottom end. Great work can’t wait to see it finished.

[@bkairys]

Thx.... kzbin.info/www/bejne/r33blYB8rZqNa5o

[@billyvray]

Looks great. Thanks for documenting! add a sub

[@travisweide9071]

Even rang the bell

[@lenBrill1971]

I'm 2 years late!!! How can I find more information on the Yamaha phaser engine build? Great engine. I'm a new subscriber and need to play catch up with all your vids. From what year to what year is desirable? Now I'll watch this video 👍

[@bkairys]

2007+ phazer is the one shown here. Bkexperimental.com and Yamaha aircraft conversion group on FB

[@treylem3]

👍

[@anthonymurrile6327]

Hi Ben.Where did you pick up your 1 wheeler board

[@embededfabrication4482]

don't see many used genesis 500 available. what year is that engine? looks like a lot of machining to get the gearbox on it, would have to pay a lot to have that done probably.

[@evopwrmods]

Throw you a little turbo on there and get maybe 10-15 more hp, plus a whole host of other benefits,. such as better power delivery, noise canceling, fuel economy, etc. etc. wouldnt add that much weight either. But this yamaha motor sure does zoom...

[@Copterworx]

I’m interested in putting one on my Benson B8M Gyrocopter... not sure if prop size will be an issue yet. How much to convert?

[@youtoo2273]

Is this ultra light ? I would be very cool to add a turbo on the engine.

[@2broketim479]

great idea! however, most people don't have the talent and resources to convert such an engine to aircraft use. the bulk of us ultralighters are stuck with "plug and play" Rotax .....

[@jimsandoval7633]

Very interesting to hear you say that you would not install this engine in your Kitfox IV because it has a 582 and the increase in power would not be worth the work. Apex is too heavy for a Kitfox IV. I have a Kitfox IV with a 582 also, and if could so a setup like you did with that Rotax gearbox, I think I would give it a try. I already have a C gearbox with me but I don't have the knowledge and experience that you have. Congratulations on with your work. I already saw your next video and it looks like you made a great setup.

[@bkairys]

I'm second guessing that statement after flying this engine. It has potential for a kitfox. Keep in mind that mine is a 1050 gross and weighs 630lbs empty.. Its heavy and I can't figure out why.

[@DavidJones-hr9bn]

Jim Sandoval, Google Rotax Rick out of Florida. Offers a Rotax 670 at 90+ HP with 2 year warranty. Same mounting pattern as your 582. $3750 with exchange for your 582.

[@sganzerlag]

@@bkairys Did you actually weigh your kitfox 4? Or are you going by what the original weight and ballance data sheet says? If you can't figure out why it's heavy, maybe that's because it isn't? Just found your youtube channel and will be following this engine project with interest. Best regards from Brasilia, Brazil.

[@clarklewis]

Hi, Ben. I have a Phazer engine sitting in my shop, just waiting on Ian Bange to modify the harness for me, and Teal’s gearbox to be available. Any chance you could share your mount design? I’d even pay to have you build one, since I can’t weld! Mine will be going on my T-Bird II, also a pusher, but with the gearbox up, replacing a 582. Subscribed and looking forward to your testing

[@bkairys]

This engine mount is custom made for a kolb. I had a Tbird 1, it was a great plane! Check my older videos.. younwould have to custom make a mount for your application which could be difficult without the aircraft on hand to do so.

[@clarklewis]

Ben Kairys 👍. My 582 has a plate mount that looks a lot like yours. Ima have to steal your basic design via some eyeball engineering.😬

[@russellsmith3825]

I am also looking at a Tierra 2 that currently has a 503, and having been let down by 2 strokes more than once, this is very interesting.

[@russellsmith3825]

@@clarklewis he might be able to scan the shape and bolt holes locations for the adapter and use someone like sendcutsend.com/ to replicate.

[@pollyannadavis9524]

Hi I live in Gowen been interested in ultralight flying

[@djal1030]

where did you get the ngine?

[@chetlovesamerica6783]

These days ,everyone is jumping on the band wagon for Yamaha snowmobile engines ,,check out Edge Performance out of NORWAY,,INTERESTING numbers on dyno.

[@rambo95777]

Hi Ben, where did you get the actual engine? can't find any used one...

[@bkairys]

Brought entire snowmobile locally. Sold rest as parts

[@MrHanowski]

Ben, Nice thinking. I'm considering this for Powered Parachute, replacing 582. What is the best source for engines? Does it have electric start? Rotax 582 needs E-box for electric start. How do you start with C-box? Is the Phazer a current engine, or must I look for particular year/model snowmobile? Thanks . . . I'll be following!

[@bkairys]

2007 and up Yamaha Phazer is the way to get all you need. Buy a donor sled is best bet.

[@MrHanowski]

@@bkairys Do you still have your 503? I know someone looking for one.

[@bkairys]

I do! He can email me at [e-mail]

[@darylbuckner5596]

@@bkairys Ben what kinda $ does a sled go for?

[@bkairys]

@@darylbuckner5596 $1500 to 4k.

[@mohamedshafeelmohamedbilal6364]

Any issue...when the gear reduction unit of propeller direct attach to fly wheel?

[@bkairys]

yes, have rk400 clutch now.

[@Stromzilla]

I think I missed something. You said you fabricated the adapter plate. Where did the gearbox come from? Off the 503?

[@bkairys]

Yes, The gearbox is a rotax C box commonly found on rotax 503 and 582s

[@Stromzilla]

@@bkairys Do you feel the gearbox will go the distance with the power increase?

[@bkairys]

Yes! There are Apex models (150hp) running these same gear boxes. Also they are rated for 140 hp by rotax.

[@Stromzilla]

@@bkairys You just made my day!!

[@Brough1111]

Interested in this engine for a build project thanks

[@bkairys]

Check out bkexperimental.com , you can contact me thru the site too.

[@WendelltheSongwriter]

Okay, so this Florida guy just figured out what a Phazer is, so I'm sort of up to speed. ( I'm a Turbowheels Dart electric kick scooter guy, myself. )

[@claytonbuckley8626]

Do you know the total weight for this engine?

[@Jason_Quinn]

8:05 he shows the weight: 108.9lbs

[@jorbedo]

What is the engine Dry weight? TIA

[@bkairys]

121 lbs depending on exhaust and airbox used.

[@Peter_Eriksson]

Look at ianslife channel on KZbin, he has a wire harness for phazer

[@travisweide9071]

Ianslife is how i have heard of phazer and now im here

[@Mike-01234]

Too bad Sky Trax box can't be flipped over mounted either way.

[@JohnDLeo-rg8tc]

Good original thinking. Lose the 1 wheel and red bull and be yourself. The world doesn't need anymore T.P.s

[@MACE1-1]

I think he's picking up the slack from the rest of the arm chair elitists...

[@DJ-mo2ur]

I'm considering one of those engines for my Taylor-monoplane. Flew with a 38 hp so 60-70 hp would be great.

[@allywilkeforsenate]

I had a shot every time he sid and,ah and so,.I am wasted now.

[@clarklewis]

Ben, can you give the part # for the Yamaha muffler you have? I’m trying to find one, and I can’t tell by looking at them online if they are titanium or not. Thanks!

[@bkairys]

This is a 2009 yamaha R1 muffler

[@glennmaxfield6618]

You made me dizzy spinning round on that thing. I lasted until 1.43 sorry

[@bkairys]

deff dont watch the flying videos then!

[@scbane]

2:44 is where info starts. Annoying intro, and a bunch of useless lead-in. Get to the point.