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I have a 2007, 80hp 912UL with 270hrs TT. It is extremely difficult to start when cold. Carbs have been completely rebuilt and synced. New plugs, new fuel pump, new battery, 91 octane auto fuel, assembly of enrichner choke verified as correct, excellent compression, fuel in carb bowl ~ 1/4" below rim before initial cold start. High wing gravity feed to fuel pump. Fuel pump is pumping fuel. All grounds and connections removed and cleaned around ignition modules, engine and firewall. Check plugs after several cranks and no do not appear wet. Engine will slow to 1560RPM when holding throttle back. Chokes are pulling to the full on position.

If and when the engine does start it hits and runs perfectly. It is like I forgot to turn the ignition switches on. Once running, restarts the same day are on first crank. Ambient Temperature during start has been 80F to 100F.

I am at my wits end trying to figure this problem out. Any suggestions would be very much appreciated.
  • Re: 80HP 912UL Initial start issue

    by » 10 years ago


    Hi William,

    What is the plug gap set at? Should be between .023 - .027.
    1560 rpm is fairly low. When that low you would have to give it some throttle to start. Too low and rpm is hard to start and too high an rpm can be if you add throttle.

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


  • Re: 80HP 912UL Initial start issue

    by » 10 years ago


    Hi Roger,
    The plug gap is about .025". I have tried throttle back, throttle cracked, fuel off, choke off/on and all combinations of the above. The engine cranks fast. There is little to no warning of when it is going to start. Just all of a sudden during one of the 3-5 sec cranks it fires up and runs smooth. No indication of being flooded. But I never know when that sudden start will occur. Yesterday I could not get it to do anything. I have even gone as far as pulling one of the wires off of each ignition switches to insure the ignitions are not grounded. Cranked it and nothing happened.

    Please let me know if you have any other suggestions.

    Kind thanks,

    Bill

  • Re: 80HP 912UL Initial start issue

    by » 10 years ago


    Because your engine is of 2007 manifacturing date one can suspect defective ignition modules, an increasingly common issue around this mamifacturing year.

    So just a little test advice:

    If you have access to other ignition modules of another engine you can try a quick swap to confirm or negate the fault ( it takes few minutes to do the swap/trial).

    Otherwise , if you have not other modules to try , prior of a cold start you can slowly warm the modules with a phon not exceeding 75 degrees celsius ( it seems a strange procedure but it had showed to discriminate rotax peculiar bad ignition modules faults). If the defect goes away you have defective cdi modules.

    Nicola di Biase

    Thank you said by: William Campbell

  • Re: 80HP 912UL Initial start issue

    by » 10 years ago


    My friend had similar problem with 582. The problem was, ignition module doesn't give ignition when cold. When we warmed up modules, everything comes ok.

  • Re: 80HP 912UL Initial start issue

    by » 10 years ago


    If you can't borrow modules and you have to buy I think you can initially buy only one and check. Engine should start only on one module.
    Check module version (there are different).

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