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I have a intermittent ignition failure on a 3 year old Rotax 912 ULS (approx 1200 hrs). During runup ignition check it will completely shut down on the right ignition. This isn't a sputter, cough thing, it just completely shuts down as if you turned off the key.

I have run diagnostics on the ignition system (Dr Rotech), replaced the ignition module and checked the ignition switch, no help. When I swap the plugs between the ignition modules and the coils the problem moves the "left" which tells me the problem is on the coil side of things. Since the engine completely shuts down, I believe it must be something in common with both coils. That pretty much narrows it down to the ground wire. I have cleaned the connection and applied lithium grease but it doesn't solve the problem.

Am I missing anything?
  • Re: 912 ULS ignition failure

    by » 11 years ago


    Tim,

    You probably already know this but I'll throw it in anyway.

    If the engine is running with both mag switches on and it completely stops when you shut down the right ignition, the left ignition is the one that is not working. From what you've tried, It indicates that both ignition modules are OK and one coil or the wiring from that coil must be the culprit.

    Good luck, let us know what you find.

    Bill.

  • Re: 912 ULS ignition failure

    by » 11 years ago


    Thanks for the reply. I don't think it can be a coil because the engine shuts down completely. If one coil were bad wouldn't it continue to fire on two cylinders? That's why I was looking at the only thing both coils share and that is a ground wire from the engine back into the ignition module. I've cleaned the connections so I'm at a loss to find the problem.

  • Re: 912 ULS ignition failure

    by » 11 years ago


    Tim,

    If one coil were bad, all four cylinders of circuit A or circuit B would be dead. In order to sinplify the ignition system, The plugs fire at the top of the compression stroke and also at the top of the exhaust stroke. Even though the engine is a four stroke, the plugs fire every time the piston come up; just like a two stroke. This makes for a much less complex system requiring only two coils.

    You have already eliminated the modules as a problem which leaves either one of the coils, the kill switch wiring, or the switch itself. Most of the time the problem will be the wiring or the switch. The heavy maintenance manual will give you the resistance values and tell you how to check the resistance in each coil to see if one is bad. If they check out OK, it just about has to be a short somewhere in the kill switch circuit.

    You can download the heavy maintenance under the support tab at the top of this page.

    Bill.

  • Re: 912 ULS ignition failure

    by » 11 years ago


    Bill,

    I'm confused. I know about the firing on each stroke but there are four coils with two plug wires per coil. Thus one coil fires the spark plugs of two cylinders. Unless there is some interaction between coils, one coil going bad should only impact the firing of two cylinders.

    I have the Dr Rotech ignition analyzer which is suppose to measure the resistances of the coils and the triggers. Everything checks ok but given the intermittent nature of the problem that doesn't help much.

    Tim

  • Re: 912 ULS ignition failure

    by » 11 years ago


    Tim,

    I was confused too. You are right, the four trigger coils control only two plugs each. The charging coils on the stator control all four plugs in ciruits A or B. I'm thinking the same thing you are. If one trigger coil was bad, The engine would still sputter and try to run on two cylinders during the mag check. If one of the two charging coils was bad, the engine would stop dead instantly during the mag check.

    It still sounds like a charging coil or wiring to me. Coils usually either work or not, but I have seen on rare occasions a coil that would work OK cold and then malfunction when hot.

    Intermittant problems are hard to find. Perhaps Roger or someone else on the forum with more experience than I will jump in here with some advice.

    Bill.

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