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Ignition Circuit Pin Removal

in 912 / 914 Technical Questions 7 years ago
I had a cylinder head bolt come out in flight and destroyed my 912 ULS. I am in the process of removing the engine for overhaul and can not figure out how to get the 6 pin connector on the ignition apart and remove a pin so that I do not have to cut the ignition wires. Please help!
2018-04-10_0918.png (You do not have access to download this file.)

  • Re: Ignition Circuit Pin Removal

    by » 7 years ago

    To pull the plastic 6 pin connector apart just use a screwdriver tip to pull back on the tap on one side of the connector and the plastic connector slides apart. Then look down inside the connector at the pins inside. You will see a small plastic Tab up against the pin that holds it in place. I use a VERY small straight screwdriver tip to push it down and away from the pin all the while I have some slight back pressure on the wire. When the clip releases the pin slides right out.
    Do not sit and dig at this little plastic connector that hold the pin in place. Constant digging may damage it and then it won't hold the pin in place any longer. You can use a flashlight and look down inside and you'll see that release for the pin.
    This is one of the skills I teach in my classes.

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

    Thank you said by: George Little, Stacy L. Kelly
      
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  • Re: Ignition Circuit Pin Removal

    by » 7 years ago

    Keep in mind that they were never intended to easily come apart.
    There is an official tool that does the job but cost $100 for almost nothing.

    This will work just fine if you have some patience, a bit of luck and a Lock Pick in your ancestery.
    This applies to connectors in general. Pins or Plugs. and most manufacturers.

    The first thing is to make the Lock Picking tool.
    A little craftwork and 5 minutes with an Xacto Blade on grinding wheel will do it.
    Reshape the point into a flat screwdriver profile


    Place this modified blade in an Xacto knife handle to make it usable.



    While looking into the Pin/Plug (Non-Wire) end of the Connector; notice that there is a gap or a slot on both sides and directly next to every Pin/Plug.
    This is where you will be inserting your new tool.
    There is a Locking Wing on both sides of each Pin/Plug that you will need to compress to allow the Pin/Plug to be extracted



    In reality, you need two Pin extractor tools and Three hands but we can make this work.
    First, insert the tool down the side of each pin to get started.
    If you press firmly the extractor will slip past the locking wings into the wire portion of the connector.
    Now, while keeping a firm tension on the Wire as if you were trying to pull it out of the rear of the Connector, reinsert the extractor tool alternating down each side if the Pin until the Pin pulls out of the back of the connector.
    You may get it to come out on the first try or it may take a dozen tries. Be patient!

    Notice: Some connectors have a secondary locking feature on the that will need to be removed before the pins will come out.


    Some are easy to identify and remove and some not obvious and quite difficult.

    Remember if all else fails, these are common connectors in the automotive world and all parts are available.
    If you plan to reuse the Pin, Be sure to Carefully pry the Locking wings back out to their 30° angle.
    Don't overdo it!
    PinRemoval1.jpg (You do not have access to download this file.)
    PinRemoval4.jpg (You do not have access to download this file.)
    PinRemoval3.jpg (You do not have access to download this file.)
    PinRemoval2.jpg (You do not have access to download this file.)

    Bill Hertzel
    Rotax 912is
    North Ridgeville, OH, USA
    Clicking the "Thank You" is Always Appreciated by Everyone.

    Thank you said by: Wayne Fowler, Stacy L. Kelly
      
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  • Re: Ignition Circuit Pin Removal

    by » 7 years ago

    A watch screwdriver would work to.

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

      
    Report

  • Re: Ignition Circuit Pin Removal

    by » 7 years ago

    see attached pdf
    de-pin_2018-04-17.pdf (You do not have access to download this file.)
      
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