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I have been having problems with a new to me 912 ULS with 1,100 hrs.  The motor has rebuilt carbs and the 5 year rubber replacement.  Since the 1st start about 2/3 the time it runs very rough.  About 1/3 the time it runs very smooth.  When running rough I have noticed the EGT for cylinder #3 is around 300 and a timing light shows no spark to cylinder #3.  Today while troubleshooting it ran great for around 5 minutes with even EGT temps for all cylinders - as soon as I did a mag check it started running extremely rough and would not smooth out when switched back to both mags.  So far I have replaced and gapped all the spark plugs.  I installed all new plug wires and caps.  I swapped two of the coils around and the problem stayed with cylinder #3.  I installed two new ignition modules. I inspected all the wires for the coils.  Since I swapped out the entire top portion of the ignition system I am thinking I must have a problem with the trigger coils.  Does anyone have thoughts on next steps?  

  • Re: no spark cylinder #3

    by » 2 years ago


    Swap a trigger coil?  Balance the carbs? 


  • Re: no spark cylinder #3

    by » 2 years ago


    The carbs are already balanaced with a carb mate and I doubt it is a carb problem because when it is running rough pulling the choke has almost no affect.  Also, I am fairly confident in my low EGT reading on the #3 cylinder.  After shutdown the exhaust on that cylinder is noticebly cooler.  I am also confident in my timing light and have double checked that so I know that when it is running rough I am not getting a spark to #3.  Whats the best way to swap a trigger coil?  Do I switch physical position and then the pin position in the 6-way?  I have looked at the gap on the trigger coil and it is not really that adjustable but have it set pretty close to the .012.


  • Re: no spark cylinder #3

    by » 2 years ago


    When you say that it runs very rough and there is no spark on #3 then I assume that the timing light shows no spark on either the top or bottom plugs. Failure of a single spark in a cylinder is unlikely to give very rough running.

    It is unlikely that you have a problem with 2 separate ignition systems. There shouldn't be any common mode failures of the ignition that give the symptoms that you describe. It could be that there was a single failure on one system some time ago and this wasn't noticed and then a second fault has developed with the second ignition system and now it is noticeable.

    I would use the diagram and resistance values published in the heavy maintenance manual and measure the resistance with a multimeter from the 6-pin connectors. Whilst doing this, pull on the various wiring harnesses to see if the resistance changes indicating a break somewhere.

    Let us know what you find.


  • Re: no spark cylinder #3

    by » 2 years ago


    Try replacing the spark plugs. Even if they test okay they can still be faulty. I’ve had brand new plugs that were defective right out of the box.


  • Re: no spark cylinder #3

    by » 2 years ago


    Did some more troubleshooting today with no resolution.  Switched spark plugs and caps for cylinder #3 with cylinder #1.  I then removed trigger coil assembly and tested coils all the way to 6-way plug.  Also took trigger switches apart and found fair amount of oil in the switch, cleaned out and everything else looked good.  I wrongly stated no spark to cylinder #3 as I am still getting spark to bottom plug.  When I reinstalled trigger coils I had problem adjusting the gap for the B3/B4 coil.  This is the coil that fires the top #3 plug.  When one flag on flywheel comes around I can gap to .012 but when the 2nd flag comes around the closest gap i can adjust is .025.  I can not see any damage or wear marks on the trigger coils or the flywheel.  I need to recheck the gap in the other trigger coils but I beleive they are good.  I potentially know why cylinder #3 is not firing but still do not know why it alternates between running rough and smooth.  I also am not sure that buying a new trigger coil is going to allow me to adjust gap to .012.  I am also wondering if my crank is not straight.


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