Roger,
I first set the idle manually by backing the screws off completely (.004 clearance) then turning in 1 and 1/2 turns (which brought them back pretty much to where they were). Would not start - violent kickbacks. I took the throttle cables off to make sure they were not holding the carbs off idle. Would not start. No option to crack the throttle to assist. In total frustration I took the carbs back off to check them out again. The engine runs beautifully and starts beautifully AFTER it starts once. It is just the first start - and it almost sounds like a timing issue with the violent kickbacks. I read your post on the high torque starters, my engine was manufactured in 2005, serial 5.644.514, would it have that starter on it? I already have the soft start module and am ready to pull that back off. Wow this is frustrating - this engine has always been a good starter and an excellent operating unit.
It sounds like you have the dreaded sprag clutch failure. I am presuming you have a slipper clutch fitted.
There is a very fine spring on the circumference of the sprag that becomes distorted when the engine kicks back. Every kick back seems to damage the spring more until it can be impossible to start.
The fix is easy, just expensive. You need to fit a new sprag clutch, two soft start ignition modules and the new type flywheel. You should also service your gearbox and set friction torque as high as is recommended (800Nm/590ft/lbs)
You need the large, gold coloured starter motor and make sure you have a good battery and leads. If the starter is black it is the smaller one that is not recommended on the 912s.
Did things run okay before the maint. You listed above. If they did then its time to check those items before anything new. I didn't think you need all new items, just check out what was already done. This may be the cause of the issues if it ran okay before the maint.
Roger Lee LSRM-A & Rotax Instructor & Rotax IRC Tucson, AZ Ryan Airfield (KRYN) 520-349-7056 Cell
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