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rOTAX 9112 ULS Mystery SOLVED ! ! !

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JohnF

Joined: 13 May 2010
Posts: 124

Posted: Sat Jun 09, 2012 9:54 am Post subject: rOTAX 9112 ULS Mystery SOLVED ! ! !

First, let me thank everyone who gave me hints,  suggestions, and views. I appreciate it far more than you might  expect.

  

 I just suspected it was something I did because the  engine was working just fine prior to starting the annual condition inspection.  But what?

  

 I went over everything folks suggested with no  positive results. 

  

 I decided to pull the plugs that were too black,  sand blast them and reinstall, or possible put back in the plugs that had been  removed earlier.

  

 I never look into the spark plug boot, the part  that connects the ignition wire to the top of the spark plug. I should have.  When I pulled #4 bottom plug's wire boot it just didn't feel right, so I got a  flashlight and examined the inside. There's a rather round receptacle and a  small wire that crosses the receptor's "hole"....that was cocked sidways, so the  top of the spark plug didn't get 'captured' by the little wire that normally  slides across the top of the plug when you insert it. That's why you hear and  feel that little washboard sound when inserting the plug.

  

 I straightened out the receptor, insured a good  'clicking' sound when re-inserting the boot and wrapped things up.

  

 The engine ran perfectly....all  normal.

  

 I went back in my trouble shooting notes (I keep  notes so I can recall what I have done, etc) and noted that on the very first  run after finishing the inspection that the engine ran rough I found #4 bottom  plug wire hanging down loose. I thought I had overlooked installing it. Now I  see it just fell out.

  

 Now during trouble shooting the engine would run  fine. Next morning it would not after reinstalling the cowling. Just putting on  the cowling was enough to jostle the #4 plug wire to break the tenuous  connection from the top of the plug to the interior of the boot.

  

 I fell so good I am going out for a pizza and a  pint of beer.

  

 Again I can't say how much I appreciate all your  help and suggestions.

  

 John

   [quote][b]

Roger Lee

Joined: 10 Jan 2006
Posts: 1464
Location: Tucson, Az.

Posted: Sat Jun 09, 2012 12:59 pm Post subject: Re: rOTAX 9112 ULS Mystery SOLVED ! ! !

Hi John,

Congratulations I know that must feel almost as good as that cold beer, maybe even better. 

Glad you found it and from my own experiences I know it has to feel good when you finally find that ghost.



Just so you know that the problem you had is one of the Line Maint. inspection checks that should be done at the annual. On the inspection check list those boots should have 7 lbs of pull pressure before they come off. 

I would recommend to every single person on our forum to print out from the Rotax Line maint. manual the inspection check list which is for the 100 hr. and the Annual condition inspection and use it every time. Sign off each check and keep them in a binder. If someone else does your inspections make them use this check list.

_________________
Roger Lee
Tucson, Az.
Rotax Instructor & Rotax IRC
Light Sport Repairman
Home 520-574-1080 TRY HOME FIRST
Cell 520-349-7056

jacklockamy(at)comcast.ne
Guest

Posted: Sat Jun 09, 2012 2:02 pm Post subject: rOTAX 9112 ULS Mystery SOLVED ! ! !

Congrats John!  

 

I appreciate YOU sharing your trouble-shooting experience with us on the List.  This is EXACTLY why I subscribed to this List in the first place.  To learn from others who may have “been there…done that”.

 

Jack in Key West

 

From: owner-rotaxengines-list-server(at)matronics.com [mailto:owner-rotaxengines-list-server(at)matronics.com] On Behalf Of JohnF

Sent: Saturday, June 09, 2012 1:52 PM

To: rotax engines matronics

Subject: rOTAX 9112 ULS Mystery SOLVED ! ! ! 

 

First, let me thank everyone who gave me hints, suggestions, and views. I appreciate it far more than you might expect.



 



I just suspected it was something I did because the engine was working just fine prior to starting the annual condition inspection. But what?



 



I went over everything folks suggested with no positive results. 



 



I decided to pull the plugs that were too black, sand blast them and reinstall, or possible put back in the plugs that had been removed earlier.



 



I never look into the spark plug boot, the part that connects the ignition wire to the top of the spark plug. I should have. When I pulled #4 bottom plug's wire boot it just didn't feel right, so I got a flashlight and examined the inside. There's a rather round receptacle and a small wire that crosses the receptor's "hole"....that was cocked sidways, so the top of the spark plug didn't get 'captured' by the little wire that normally slides across the top of the plug when you insert it. That's why you hear and feel that little washboard sound when inserting the plug.



 



I straightened out the receptor, insured a good 'clicking' sound when re-inserting the boot and wrapped things up.



 



The engine ran perfectly....all normal.



 



I went back in my trouble shooting notes (I keep notes so I can recall what I have done, etc) and noted that on the very first run after finishing the inspection that the engine ran rough I found #4 bottom plug wire hanging down loose. I thought I had overlooked installing it. Now I see it just fell out.



 



Now during trouble shooting the engine would run fine. Next morning it would not after reinstalling the cowling. Just putting on the cowling was enough to jostle the #4 plug wire to break the tenuous connection from the top of the plug to the interior of the boot.



 



I fell so good I am going out for a pizza and a pint of beer.



 



Again I can't say how much I appreciate all your help and suggestions.



 



John

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  [quote][b]

jacklockamy(at)comcast.ne
Guest

Posted: Sat Jun 09, 2012 2:07 pm Post subject: rOTAX 9112 ULS Mystery SOLVED ! ! !

Roger,



For those not familiar with the checklist you mentioned, is it possible you

could post a copy (or at minimum... email me a copy)?



Thanks,

Jack

1pelican(at)comcast.net



--

BARRY CHECK 6

Joined: 15 Mar 2011
Posts: 738

Posted: Sat Jun 09, 2012 4:30 pm Post subject: rOTAX 9112 ULS Mystery SOLVED ! ! !

John:



When all else fails - STICK TO THE BASICS.

AIR - FUEL - SPARK - TIMING

The little stuff only improves what is already working.

 I'm smiling because the problem was found, ...

Glad I could help.

Barry



On Sat, Jun 9, 2012 at 6:00 PM, Jack Lockamy <jacklockamy(at)comcast.net (jacklockamy(at)comcast.net)> wrote:

 [quote]

Congrats John!   

 

I appreciate YOU sharing your trouble-shooting experience with us on the List.  This is EXACTLY why I subscribed to this List in the first place.  To learn from others who may have “been there…done that”. 

 

Jack in Key West 

  

From: owner-rotaxengines-list-server(at)matronics.com (owner-rotaxengines-list-server(at)matronics.com) [mailto:owner-rotaxengines-list-server(at)matronics.com (owner-rotaxengines-list-server(at)matronics.com)] On Behalf Of JohnF

 Sent: Saturday, June 09, 2012 1:52 PM

To: rotax engines matronics

Subject: rOTAX 9112 ULS Mystery SOLVED ! ! ! 

  

First, let me thank everyone who gave me hints, suggestions, and views. I appreciate it far more than you might expect. 



 



I just suspected it was something I did because the engine was working just fine prior to starting the annual condition inspection. But what? 



 



I went over everything folks suggested with no positive results.  



 



I decided to pull the plugs that were too black, sand blast them and reinstall, or possible put back in the plugs that had been removed earlier. 



 



I never look into the spark plug boot, the part that connects the ignition wire to the top of the spark plug. I should have. When I pulled #4 bottom plug's wire boot it just didn't feel right, so I got a flashlight and examined the inside. There's a rather round receptacle and a small wire that crosses the receptor's "hole"....that was cocked sidways, so the top of the spark plug didn't get 'captured' by the little wire that normally slides across the top of the plug when you insert it. That's why you hear and feel that little washboard sound when inserting the plug. 



 



I straightened out the receptor, insured a good 'clicking' sound when re-inserting the boot and wrapped things up. 



 



The engine ran perfectly....all normal. 



 



I went back in my trouble shooting notes (I keep notes so I can recall what I have done, etc) and noted that on the very first run after finishing the inspection that the engine ran rough I found #4 bottom plug wire hanging down loose. I thought I had overlooked installing it. Now I see it just fell out. 



 



Now during trouble shooting the engine would run fine. Next morning it would not after reinstalling the cowling. Just putting on the cowling was enough to jostle the #4 plug wire to break the tenuous connection from the top of the plug to the interior of the boot. 



 



I fell so good I am going out for a pizza and a pint of beer. 



 



Again I can't say how much I appreciate all your help and suggestions. 



 



John

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[b]

Roger Lee

Joined: 10 Jan 2006
Posts: 1464
Location: Tucson, Az.

Posted: Sat Jun 09, 2012 7:20 pm Post subject: Re: rOTAX 9112 ULS Mystery SOLVED ! ! !

Hi All,



Here is a copy of the inspection check list right out of the Rotax Line maint. manual. You should get in the habit of always using it.

Rotax Maint Check List.pdf

Description:

Rotax Line Maint. Check List

Download

Filename:

Rotax Maint Check List.pdf

Filesize:

68.45 KB

Downloaded:

419 Time(s)

_________________
Roger Lee
Tucson, Az.
Rotax Instructor & Rotax IRC
Light Sport Repairman
Home 520-574-1080 TRY HOME FIRST
Cell 520-349-7056

Dick Maddux

Joined: 24 Jun 2008
Posts: 516
Location: Milton, Fl

Posted: Sun Jun 10, 2012 4:25 am Post subject: rOTAX 9112 ULS Mystery SOLVED ! ! !

John,

  Ahh haa ! I thought it might be a plug problem but didn't think about  the cap not connecting. Thanks for sharing as that is another item I can add to  trouble shooting . Now if I could only remember !

  Roger, stay young and sharp !

                                            Dick Maddux

                                            Milton,Fl

 [quote][b]

Roger Lee

Joined: 10 Jan 2006
Posts: 1464
Location: Tucson, Az.

Posted: Sun Jun 10, 2012 4:38 am Post subject: Re: rOTAX 9112 ULS Mystery SOLVED ! ! !

Hi Dick,



Nice to hear from you. Hope all is well.



The young part is the hard part. Still in a holding pattern at 39 (for 19 years), if I could only make my wife believe it.

_________________
Roger Lee
Tucson, Az.
Rotax Instructor & Rotax IRC
Light Sport Repairman
Home 520-574-1080 TRY HOME FIRST
Cell 520-349-7056

kgderosier(at)gmail.com
Guest

Posted: Sun Jun 10, 2012 6:27 am Post subject: rOTAX 9112 ULS Mystery SOLVED ! ! !

I, to am happy with this group staying on topic.  Everyone had great suggestions for John which I will keep in my archives.  John , I'm sure it feels really good to have the help that you got.

  

 Gale Derosier

 RANS S6-S Coyote II

 912 UL

 On Sat, Jun 9, 2012 at 12:52 PM, JohnF <n29cx(at)ridgeviewtel.us (n29cx(at)ridgeviewtel.us)> wrote:

  	  Quote: 	
		    First, let me thank everyone who gave me hints, suggestions, and views. I appreciate it far more than you might expect.

  

 I just suspected it was something I did because the engine was working just fine prior to starting the annual condition inspection. But what?

  

 I went over everything folks suggested with no positive results. 

  

 I decided to pull the plugs that were too black, sand blast them and reinstall, or possible put back in the plugs that had been removed earlier.

  

 I never look into the spark plug boot, the part that connects the ignition wire to the top of the spark plug. I should have. When I pulled #4 bottom plug's wire boot it just didn't feel right, so I got a flashlight and examined the inside. There's a rather round receptacle and a small wire that crosses the receptor's "hole"....that was cocked sidways, so the top of the spark plug didn't get 'captured' by the little wire that normally slides across the top of the plug when you insert it. That's why you hear and feel that little washboard sound when inserting the plug.

   

 I straightened out the receptor, insured a good 'clicking' sound when re-inserting the boot and wrapped things up.

  

 The engine ran perfectly....all normal.

  

 I went back in my trouble shooting notes (I keep notes so I can recall what I have done, etc) and noted that on the very first run after finishing the inspection that the engine ran rough I found #4 bottom plug wire hanging down loose. I thought I had overlooked installing it. Now I see it just fell out.

   

 Now during trouble shooting the engine would run fine. Next morning it would not after reinstalling the cowling. Just putting on the cowling was enough to jostle the #4 plug wire to break the tenuous connection from the top of the plug to the interior of the boot.

   

 I fell so good I am going out for a pizza and a pint of beer.

  

 Again I can't say how much I appreciate all your help and suggestions.

  

 John

 	  Quote: 	
		  



ist" target="_blank">http://www.matronics.com/Navigator?RotaxEngines-List

ttp://forums.matronics.com

_blank">http://www.matronics.com/contribution



	


	


-- 

Gale Derosier

  [quote][b]

mortweaver(at)sbcglobal.n
Guest

Posted: Sun Jun 10, 2012 6:49 am Post subject: rOTAX 9112 ULS Mystery SOLVED ! ! !

Thought I would comment on something else you may not be aware of when doing spark plug maintenance.  The terminal connector in the plug boot should be coated with electrical connector grease.  Dry terminals where high voltage is present combined with high humidity such as atmospheric foggy conditions can contribute to electrolysis in high voltage plug wire connectors(resulting voltage drop at connection will cause local hot spot and accelerate electrolysis process leading to destruction of connector base metals).  By preventing any moisture wetting of dissimilar base metals in the connection with application of appropriate grease, electrolysis can be prevented.  A sound plug wire connection on the Rotax 912 is noted by an audible clicking sound as the spark plug lead connector slips over the spark plug  terminal threads.  If that sound is not present, then close inspection of inside of boot terminal is required.  

 Dave Weaver N912GR     



--- On Sat, 6/9/12, JohnF <n29cx(at)ridgeviewtel.us> wrote:



  	  Quote: 	
		  

From: JohnF <n29cx(at)ridgeviewtel.us>

Subject: rOTAX 9112 ULS Mystery SOLVED ! ! !

To: "rotax engines matronics" <rotaxengines-list(at)matronics.com>

Date: Saturday, June 9, 2012, 12:52 PM



     First, let me thank everyone who gave me hints, suggestions, and views. I appreciate it far more than you might expect.

  

 I just suspected it was something I did because the engine was working just fine prior to starting the annual condition inspection. But what?

  

 I went over everything folks suggested with no positive results. 

  

 I decided to pull the plugs that were too black, sand blast them and reinstall, or possible put back in the plugs that had been removed earlier.

  

 I never look into the spark plug boot, the part that connects the ignition wire to the top of the spark plug. I should have. When I pulled #4 bottom plug's wire boot it just didn't feel right, so I got a flashlight and examined the inside. There's a rather round receptacle and a small wire that crosses the receptor's "hole"....that was cocked sidways, so the top of the spark plug didn't get 'captured' by the little wire that normally slides across the top of the plug when you insert it. That's why you hear and feel that little washboard sound when inserting the plug.

  

 I straightened out the receptor, insured a good 'clicking' sound when re-inserting the boot and wrapped things up.

  

 The engine ran perfectly....all normal.

  

 I went back in my trouble shooting notes (I keep notes so I can recall what I have done, etc) and noted that on the very first run after finishing the inspection that the engine ran rough I found #4 bottom plug wire hanging down loose. I thought I had overlooked installing it. Now I see it just fell out.

  

 Now during trouble shooting the engine would run fine. Next morning it would not after reinstalling the cowling. Just putting on the cowling was enough to jostle the #4 plug wire to break the tenuous connection from the top of the plug to the interior of the boot.

  

 I fell so good I am going out for a pizza and a pint of beer.

  

 Again I can't say how much I appreciate all your help and suggestions.

  

 John

 	  Quote: 	
		  



ist" rel=nofollow target=_blank>http://www.matronics.com/Navigator?RotaxEngines-List

et=_blank>http://forums.matronics.com

llow target=_blank>http://www.matronics.com/contribution



	




	
 [quote][b]

raybot(at)comcast.net
Guest

Posted: Sun Jun 10, 2012 8:57 am Post subject: rOTAX 9112 ULS Mystery SOLVED ! ! !

I followed this story and what I don,t get is why  the engine did not develop full power or close to it with both mags hot.That is  the premise of dual ignition,plus the mag drop was excessive on both mags,why?  One mag was a 4 cylinder and the other was a 3 cylinder?  I,m out of the  rotax area now and in to the lycoming but stay with this group for it all around  expertise in stuff like this.

 [quote]   ---

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