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Dick Maddux
Joined: 24 Jun 2008
Posts: 516
Location: Milton, Fl
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 Posted: Tue May 24, 2011 3:05 am Post subject: urgent: 912S ignition failure |
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Remi,
I had this happen and the failure was in the red power wire from the back of the engine to the module. I found it by using an ohm meter with a sewing pin attached at one end of a lead and grounded at the other lead. I worked my way along the wire from the module punching thru the plastic wire shielding with the tip of the pin until I found the internal wire break. It was on a flat run a few inches from the connector. It was totally invisible from the outside of the wire
I cut the wire,spliced it ,and that fixed the problem.
Good luck to you
Dick Maddux
912UL
Milton,Fl
[quote][b]
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jonathan(at)entry.co.za
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| Posted: Tue May 24, 2011 3:43 am Post subject: urgent: 912S ignition failure |
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I had the exact same problem, first the one red wire, then the next, for the two ignition systems.
The break was inside the insulation, and one could NOT see it from the outside at all.
Jonathan
From: Catz631(at)aol.com (Catz631(at)aol.com)
Sent: Tuesday, May 24, 2011 1:02 PM
To: rotaxengines-list(at)matronics.com (rotaxengines-list(at)matronics.com)
Subject: Re: urgent: 912S ignition failure
Remi,
I had this happen and the failure was in the red power wire from the back of the engine to the module. I found it by using an ohm meter with a sewing pin attached at one end of a lead and grounded at the other lead. I worked my way along the wire from the module punching thru the plastic wire shielding with the tip of the pin until I found the internal wire break. It was on a flat run a few inches from the connector. It was totally invisible from the outside of the wire
I cut the wire,spliced it ,and that fixed the problem.
Good luck to you
Dick Maddux
912UL
Milton,Fl
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[quote][b]
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hhobbit
Joined: 26 May 2011
Posts: 5
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| Posted: Fri May 27, 2011 12:43 am Post subject: Re: urgent: 912S ignition failure |
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At my last annual, the mechanic warned me to watch for wiring trouble due to vibration. We put extra cable ties around the module connectors to prevent relative movement.
Now you guys have probably seen clear wire insulation with a colour stripe along its length. Its got to be a no brainer when it comes to preventing a hidden fracture, so come on manufacturers, adopt this suggestion wherever an internally broken wire is a hazard! At a stroke we could put an end to this worry.
Is there any aftermarket supplier who could make harnesses to that specification? And any idea of the price?
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Remi Guerner
Joined: 14 Dec 2010
Posts: 284
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| Posted: Fri May 27, 2011 12:17 pm Post subject: Re: urgent: 912S ignition failure |
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I am still troubleshooting my ignition system. I am now suspecting the charging coils. Unfortunately the Rotax Maintenance manuals does not provide any indication on the characteristics of these coils except for their resistance value, which I found to be ok. What I need is the voltage delivered versus the crankshaft speed in the 200-500 RPM range.
Has anybody access to this information?
Remi Guerner
Europa F-PGKL, grounded courtesy of Rotax
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daberti(at)sbcglobal.net
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| Posted: Tue Jun 07, 2011 10:34 am Post subject: urgent: 912S ignition failure |
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Not approved for aircraft use....
--
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hletkeman
Joined: 29 Jun 2011
Posts: 8
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| Posted: Tue Jul 05, 2011 11:50 am Post subject: Re: urgent: 912S ignition failure |
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My 912 stopped charging, and when I checked the yellow cables from the stator, they were fused together. I soldered new cables on. After I replaced the yellow cables, the charging worked fine, but then it only fired on one mag. I then checked the cables from the stator to the ignition box, and found them to be fused together. The insulation on them was soft and could be pealed away with a finger nail. I changed them too, and will keep an eye on them. I believe rotax had a recall on these stators 10 years ago. Attached is a picture of my red cables
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rickofudall
Joined: 19 Sep 2009
Posts: 1392
Location: Udall, KS, USA
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| Posted: Tue Jul 05, 2011 2:07 pm Post subject: urgent: 912S ignition failure |
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You might want to check the output of the dynamo (alternator) and use a scope to see if your regulator is failing and allowing AC into your system. Have you noticed any battery charging issues? Is there anything else on this circuit that could be drawing a lot of amps and / or shorted? Whatever caused it certainly let the smoke out of the wires.
Rick Girard
On Tue, Jul 5, 2011 at 2:50 PM, hletkeman <hletkeman(at)spanishlookout.bz (hletkeman(at)spanishlookout.bz)> wrote:
| Quote: | --> RotaxEngines-List message posted by: "hletkeman" <hletkeman(at)spanishlookout.bz (hletkeman(at)spanishlookout.bz)>
My 912 stopped charging, and when I checked the yellow cables from the stator, they were fused together. I soldered new cables on. After I replaced the yellow cables, the charging worked fine, but then it only fired on one mag. I then checked the cables from the stator to the ignition box, and found them to be fused together. The insulation on them was soft and could be pealed away with a finger nail. I changed them too, and will keep an eye on them. I believe rotax had a recall on these stators 10 years ago. Attached is a picture of my red cables
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Zulu Delta
Mk IIIC
Thanks, Homer GBYM
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daveaustin2(at)primus.ca
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| Posted: Tue Jul 05, 2011 5:32 pm Post subject: urgent: 912S ignition failure |
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Did you recently de-grease or wash the area with solvent of some kind? Rotax told me years ago that
that was the cause of the problem.
Dave austin 912 HDS
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