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Background:
912UL, 200 TT, recently brought back to service after a long restoration
Dynon D180
Kitfox IV

Problem:
When doing ignition check one module has ~50 rpm drop and other has 400-600 rpm drop with skyrocketing EGT on #3 & 4 (only ones monitored, will quickly pass 1600º).

Attempted Fixes:
New Spark Plugs
Removed, rebuilt, synchronized carbs
Trimmed Spark Plug wires and checked boots - 4.5-5.9K ohms
Used inductive timing light to check for spark on all leads, checked good

Any ideas would be greatly appreciated!
  • Re: Help! Ignition Gremlin?

    by » 8 years ago


    More work done today.

    Removed, cleaned and reassembled all ground connections
    Confirmed firing order and routing of spark plug leads
    Removed Ignition modules, inspected wiring for breaks and corrosion on plugs

    All these things were done with no effect on the problem.

    After speaking with the Tech people at LEAF, CPS and Lockwood, I removed the modules again and sent them to Lockwood for testing. At this point I almost hope that one of the $1225 units is bad, then I would at least have an answer to what the problem is!


    (I think the going rate for a kidney is about $1500 and I still have both of mine, so…)

  • Re: Help! Ignition Gremlin?

    by » 8 years ago


    did the trigger coils get removed/reinstalled?
    double check they are in the correct position with the A triggers raised on the spacers.
    Or:
    Double check the CDI to coil is correct:

    912triggers.pdf.pdf (You do not have access to download this file.)
    coillayout.pdf (You do not have access to download this file.)

  • Re: Help! Ignition Gremlin?

    by » 8 years ago


    The trigger coil and flywheel assembly were never taken apart or disturbed.

    The CDI to coil connections were checked as were the coil to plug connections. All was per the heavy maint manual. Keeping mindful of the yellow and white wires from the CDIs to their proper coils.

  • Re: Help! Ignition Gremlin?

    by » 8 years ago


    The problem may be the fact that you have wired it up the way it says in the Rotax manual.

    There are 16 mistakes on the wiring diagram.

    I have emailed Rotax but heard nothing back which is what I expected.

    Try following this amended and correct diagram and lets hope you haven't done any permanent damage.


    Scan.jpeg (You do not have access to download this file.)

  • Re: Help! Ignition Gremlin?

    by » 8 years ago


    Thanks, Mark. I've seen your diagram in the other thread and will take it under advisement.

    My modules however, are the older 4-pin plug style (Fig. 74-21, pg 31 HMM)

    74-21.pdf (You do not have access to download this file.)

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