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Hi, I have a 912 ULS in my Europa. Warp Drive ground adjustable prop. Most of the time it runs beautifully but I have noticed an issue. When the "airflow is driving the propeller" for want of a better expression, ie. in a high speed, low power descent, a bad high frequency resonating vibration can suddenly start. I've noticed it many times when at cruising speed and throttling back for descent it can suddenly start. A binding throttle cable I've thought in the past, although I have worked on the cables many times and am happy with them. However, experimenting in the air at height I can make it do it by increasing airspeed alone without touching the throttle. If I set the plane up at low speed, (70 kts) and low to mid power, say 4000rpm then start to dive to increase airspeed, a point can be suddenly reached, usually 100 kts + when this vibration suddenly starts - it's more like a very noticeable change in the engine note and is so sudden it's like turning on a switch! It's teeth chattering and the slip ball jiggles about like a pea on a drum! Raising the nose to slow down again and the vibration will suddenly stop again at exactly the same airspeed trigger point as it started and it's back to normal, smooth again.
Take off, climb and cruise it never does it. Only as I say at higher speeds and low ish rpm it can suddenly start. The only way I can guarantee not to experience it on a flight is to make a lower speed descent than normal, ie. my normal cruise is 120 kts at 5,300 Rpm. If I raise the nose to slow down to less than 100 kts THEN throttle back to descend it doesn't do it and I can then descend as required without getting the vibration.
It's a problem that I know about and have been living with by trying to avoid it but just wondered if anyone might be able to shed some light on it.
Cheers!
Ps. Very happy with the carb synch (following much advice on here! Prop set up is also good and no known suspected problem with engine mounts (3 years old).
  • Re: Rough running question

    by » 10 years ago


    How old is the engine? Maybe time for a gearbox inspection?

    The gearbox may need a re-shim, the prop may need a dynamic balance (balanced while running). I would at least double check each blade to make sure they are equal pitch. This one would only take a few minutes.

    It is possible it may just be some harmonic vibration with the prop when unloaded like this and when it loads back up it disappears?

    This doesn't sound quite like a carb or mount issue.

    Anyone else with some ideas?

    Roger Lee
    LSRM-A & Rotax Instructor & Rotax IRC
    Tucson, AZ Ryan Airfield (KRYN)
    520-349-7056 Cell


  • Re: Rough running question

    by » 10 years ago


    I agree Roger, it is likely the gearbox. Look for excessive wear on the dog hub; if the dog gear has worn a "pocket" into the dog hub they should both be replaced. Kudos to Lockwood for identifying this condition.

  • Re: Rough running question

    by » 10 years ago


    Hi Jonathan,

    Your symptoms sound very similar to those that I had last year. After trying everything I removed the gearbox and sent it away for inspection. The result was a severely worn prop shaft and dog gear. Rebuilding the gearbox although not cheap resolved the vibration.

    The main symptom of my problem was vibration when the throttling back and unloading the propeller. This must have been due to the play in the splines. Once the problem started it just got worse and worse until it was no longer enjoyable to fly the plane.

    Good luck!

    Kevin

  • Re: Rough running question

    by » 10 years ago


    Hi Roger, Rob & Kevin,
    Many thanks for your replies on this. It does sound like having my gearbox looked at should be a winter project (nearly there now..!). Roger, my engine is a 2002 model with 280 hours total time. I am happy with the propeller pitch having adjusted/ checked them several times. I have never had it dynamically balanced though having bought it new 3 years ago.
    Since owning my Rotax I have tried to learn as much as possible about it by reading the manuals and this (very useful) forum but for me the gearbox is still a black art - I must admit I do get confused with all the versions and maintenance requirements thereafter. Mine is a 912ULS without an overload clutch - version 2 I think. Is an overload clutch the same term for slipper clutch? Does "re-shimming" apply to any gearbox regardless of overload clutch or not? Is this relating to the "Bellville" washers that I have heard about but do not know what they are?!
    Also, is "friction torque" the same as "slipper torque" and do either of these terms apply to a gearbox without an overload clutch?
    Best Regards, Jon

  • Re: Rough running question

    by » 10 years ago


    I guess Roger is busy so I will try to answer:
    -Yes, overload and slipper clutch are the same thing.
    -Yes, you need to re-shim all gearboxes. This is just increasing the disc spring pressure by adding thin, washer shaped shims. see item 15
    -Not sure how the term "belville" washers came to be used. they are called disc springs. see item 10 & 13. Maybe because they are beveled (curved/cupped surface) this was translated to belville?
    -Friction torque is the measurement of how much disc spring force is being exerted. Slipping torque is the measurement of how much force is required to break-away the overload clutch item 8

    Gearboxparts.jpg (You do not have access to download this file.)

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