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My 80HP 912 Rotax had a mag check failure at run up.
First mag drop was almost nill, second mag was an erratic and rough running engine. Classic symptom of a module failure. I pulled the 4pin connectors and swapped them, no change. I pulled the ignition leads from the panel and swapped them and was able to swap the failure from mag 2 to mag 1. So I thought I had isolated the problem to the ignition wire from the panel/mag switch.
Figured this was the problem so I ran a new wire and bullet connector from the connection, test was negative. Did the same for the other bullet connector and still having the same issue. I did a continuity test on the switches and both checked out. could the switch be bad anyway? I'm now lost. Ideas? :(
  • Re: Ignition problem 912 80 hp

    by » 8 years ago


    Today I had a similar problem. Really I experienced this problem two weeks ago and I thought to have solved it. But now I have again the problem but I am confident to have found the cause.
    My is an 80HP with 1500 hours. Testing the ignitions before flight two weeks ago I got the engine with erratic running and then shutting down by switching one of the ignition swithes. The other one did not give the usual small rpm variation.
    The connector of the red wire(the one who provides power to the module) on one of the ignition modules come lose by simply pulling the wire. I welded it and apparently the problem was solved. Today again the same problem on the same module. I checked again the red wire continuity until I discovered an hidden wire interruption at about two inches away from the connector in the direction of the stator.
    The interruption was not visible because of the wire sheathing
    By pulling the red wire in the area were I suspected the interruption I broke it. This means that the wire was interrupted.
    I know from other friends that these red wires are prone to such a kind of breaking.
    In the case of the connector the problem arises because of the crimping and the repeated thermal expansions of the wire. The same cause should be for the wire.
    Tomorrow I will weld the wire and let you know but I am pretty sure the problem was there as the ignition modules are both working.
    I determined that by inverting the red wires. I got the shut down by the other switch.
    I'll let you know...

  • Re: Ignition problem 912 80 hp

    by » 8 years ago


    I'm here again after the repair.
    I confirm what I said in the previous post.
    The cause was a broken red wire.
    Made a junction and the engine is ok again!

    Thank you said by: jay white

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