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New 912S on a trike. No air box. Typically fly at 5000 to 8000 MSL. Since I received it from the factory I have had significant fuel leaking out the air intake filters. This is driving me crazy. I can smell fuel during my flights, mainly when I go from full throttle to idle.
I have clearly diagnosed this and NOT coming from the carb bowl vent lines. With a new installation, the experts said to flush the fuel system/carb for new installation debris, make sure the float valve needle is clean/seating (we took it apart and cleaned plus saw a slight even wear ring with a magnifying glass around the tip to assure it is seating). We synced the carbs. All the suggestions. Still the same problem. Fuel coming out the air filters.
My ROTAX mechanic thinks it is too much pressure overriding the float valve needle so I am going to install a pressure gage to see where we are at. My research shows that if there is too high a pressure you can adjust/decrease fuel pressure by changing/increasing the orifice of the adapter sleeve (which I assume is the restrictor jet in the installation manual 73-000-00 page 3) on the fuel return line.
Does it sound like I am on the right track? If I have too much pressure, would this cause fuel to be coming out my air filters? Any other experience with this?
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  • Re: Fuel venting/dripping out air filter/intakes 912S

    by » 11 years ago


    This same problem caused me to make a forced landing as I thought that I had a major fuel leak in the fuel plumbing going through the cockpit. The resultant landing caused $150k AUD in damage. My engine resides in a top end motor glider where the engine is switched on and off in flight quite often. I have just learned to live with it but not happy. Thank god for a good insurance company and an understanding friend as co-pilot who was the first to declare a problem.

  • Re: Fuel venting/dripping out air filter/intakes 912S

    by » 11 years ago


    Hi Paul,

    I would check my fuel pressure, you may have a bad needle valve, replace the bowl gaskets, you may need to adjust the float arms to achieve the proper float level.

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


  • Re: Fuel venting/dripping out air filter/intakes 912S

    by » 11 years ago


    Yes I "think" have checked both the bowl gaskets (it is leaking out the air intakes/filters) float arm level (pulling the carb bowls after running has the fuel level where it is suposed to be) and both OK. My next step will be to check the fuel pressure which I suspect may be a the problem. I think my return line goes back to the fuel supply system after the fuel flow sensor not back to the fuel tank. With this configuration would a restrictor jet adjustment lower the fuel pressure?

  • Re: Fuel venting/dripping out air filter/intakes 912S

    by » 11 years ago


    Roger,
    I will not rule out a bad needle valve but how would I test to check/verify if it is bad?

  • Re: Fuel venting/dripping out air filter/intakes 912S

    by » 11 years ago


    The only way to really test the needle valve is to replace it. The only way to really check the float level is to pull the carbs. Turn them upside down and measure the float arm height from the edge of the bowl lip. It should be 10.5mm from the edge of the bowl to the top of the float arm. You need to check both sides to make sure the float arms are not bent. Check the fuel pressure too. If you don't do these steps you may look for your problem for a long time and throw needless money at it.

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


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