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I have a 912 ULS with 65 hours and a 1 month old PC680 battery. I replaced the battery thinking it was the cause of the problem. After replacing the battery, the engine started a couple of times with no problem.

On a couple of subsequent tries to start the engine, the prop/engine would rotate 1/4 to 1/2 revolution and stop. I've checked connections, voltages and resistances in the starting circuit with no obvious problem. The starter solenoid is functioning properly. I'm getting 10.7 - 10.8 volts at the battery when cranking which I understand is ok.

To check the starter, I disconnected it from the battery with the ignition switch off and jumpered it to a car battery. With the car battery. the prop/engine rotated at a speed that would have started the engine if the ignition was on. So the starter seems ok. After disconnecting the car battery and reconnecting the plane battery, the engine started with no problem. A couple of days later, the engine started easily and I flew for an hour. Today, one week later, the engine again would not start with the prop/engine rotating 1/4 to 1/2 revolution and stopping. I've been keeping the battery on a smart charger during this period.

Any suggestions on what the problem might be or other ways to troubleshoot? Do Rotax starters have an issue with intermittent failure? We have had quite a bit of wet weather and although the plane is hangered, some water does get on the floor. Could this be a factor?

Thanks in advance. Rich
  • Re: Intermittent Starting Problem

    by » 6 years ago


    ... I'm getting 10.7 - 10.8 volts 'At the Battery' when cranking which I understand is ok...


    What voltage are you seeing 'At the Starter' when it doesn't crank?

    Any slight resistance will kill the starter.
    Even 0.1 Ohm will be fatal and can not be measured with a common Ohmmeter.

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


  • Re: Intermittent Starting Problem

    by » 6 years ago


    You need to completely rule the battery in or out as the cause. If it's not the battery then move on to the next item.
    You could still just have a bad battery. If you jump the battery and it starts okay then no matter how new the battery may seem it's bad. You may not be getting a good charge to the battery while flying. If the engine doesn't start on the first crank as you describe, stop. Hook up the jumpers and if it pops right over then I'd call the supplier of that battery and get a new one. I have seen bad new batteries.

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


  • Re: Intermittent Starting Problem

    by » 6 years ago


    Could be some "dark current" draining down your battery after the Master is shut off? Lots of videos on how to check for this on YouTube -- look up "Automotive Dark Current". A quick check is to disconnect one of your battery's primary leads (NEG is best but POS works if you are careful) right after you have flown the plane and the generator/alternator has supposedly brought the battery up to full charge. Then on the next flight (a week or so later) reconnect the lead and see if the battery has held its full charge and normally starts the engine.

    Also, based on my RV-12 / 912 / PC680 operating experience: 1) It is best if the aircraft is regularly flown to keep the battery charged; 2) The 680 holds a full charge very nicely for well over a month or more; 3) Smart chargers seem to only kick in if the battery is really low on charge; and 4) I believe that the constant use of trickle chargers does the battery more harm than good. That's my 2 cents!

  • Re: Intermittent Starting Problem

    by » 6 years ago


    Never use a trickle charger. A smart charger will bring the battery to full charge and maintain it there. Try checking all battery connections. Take them apart and reassemble with a light coat of dilithium grease. Examine the full length of your cables. Look for any chafing. The ground connections also. With water coming into your hangar enough to wet your floor corrosion of electrical connections is possible.

    Good luck

    Alan

  • Re: Intermittent Starting Problem

    by » 6 years ago


    Thanks for the responses guys. Turns out it was a bad connection on one of the starter/battery cables. I disconnected and cleaned all of them and then engine the started. All of the connections appeared clean and tight so, you're right, it takes very little to cause a starting problem. Thanks again. Rich

    Thank you said by: RotaxOwner Admin

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