Stator replacement help

by Dennis Urban in 912 / 914 Technical Questions 6 years ago

Are all 912 stators the same? If I replace my stator, must I use the stator part number (996.534) listed in SB-912-026 (my 912UL SN 4005199 is in Group C)? I don’t see that stator PN with any of the suppliers, although they do carry other PN stators. Which stators or stator kits can I use?

Can stators be rebuilt? Does anyone know a rebuild shop? How about used stators on ebay or Barnstormers?

Does anyone have any special advice when working on or replacing the stator?

Background: The charging circuits work fine, but both ignition outputs show infinity ohms (and of course there is no spark). Mandatory Tech Bulletin 912-02 seems to address this open circuit issue for my SN; and since this TB was not documented as being complied in the logbooks, I was hoping. However, when I removed the engine to comply with this TB, I noticed that one of the two thin wire coils in the stator has wires hanging loose. I don’t think this can be right, which is why I am looking at replacing it.

Re: Stator replacement help

by Bill Hertzel » 6 years ago

Bill Hertzel

13 1.95k 7.96k

Download the current copies of the Maintenance and Parts manuals for your engine.

According to SI-912-013 (Apr 2004), the stator was changed to a universal part for all engines.
The current 912UL Parts Manual shows 891095(New) and 888675(Old) as options for the 912UL.
The connectors ARE different, check the manual to match your Ignition Modules. (Hard Start?, Soft Start?)

This was supposed to have been done 19 years ago.
What else hasn't been done?
Have a look at Si-912-020 and SI-912-028 while you are at it.

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

Thank you said by: Dennis Urban

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Re: Stator replacement help

by Dennis Urban » 6 years ago

Dennis Urban

17 30 48

Thanks Bill. I appreciate your help very much. And I agree “what else hasn’t been done”. All your advice is helpful and pointing me in the right direction.

I had read that SB about standardization, but my SN (4,005.199) comes before the list of ‘Engines affected’ SNs (912A from SN 4,410.630), so I did not think it applies. I have Ducati ignition modules and new style pickups with 4 pin connectors. The stator connects via two single bullet connectors on the red leads direct to the Ducati ignitions. Nothing is easy and I am still unsure of what stator I need – I suspect with connector changes, any.

“What else hasn’t been done” is still bugging me, and since you brought it up... I had tried to go through all SBs. Things like the following bother me. When I bought my Rans S-7 (with 912UL), it constantly smelled of fuel, although no leak could be seen. About a year ago I did a complete 5-year rubber replacement (Gates Barricade and Parker oil line, and the standard CPS coolant hoses) using fire sleeve (band-it clamps, oetiker clamps) including a new fuel pump (and checking the psi at all static RPMs as req’d in the manual) and full carb rebuilds including the throttle shaft o-rings; the only thing I could not bear to buy/replace was the $82 - 1.2 bar radiator cap (which still bugs me, so I will probably do it even though the current 1.2 bar cap works fine). I might order the cap when I order the stator.

During the rubber replacement, I found that the A&P who logged the previous fuel line replacement had failed to install any (as in no!) fuel line clamps on the pressurized ¼” fuel lines under the firesleeve, and they wept enough to smell, but not see. And he sealed the firesleeve with safety wire. Pressurized fuel/no clamps, wow…. scary. Leakdown and automotive compression test results are great. But still, I wonder how much to trust. 50 hr oil changes were logged. I would be happier with a brand new engine I could control, but this one only has 420 hrs (200 hrs by me), runs great except for the current stator issue. I suspect that something must have gotten into the unshielded stator to rip at the coil wires. I plan to buy a shield.

Thanks,
Dennis

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Re: Stator replacement help

by Bill Hertzel » 6 years ago

Bill Hertzel

13 1.95k 7.96k

The SB "From" means all engines AFTER that number will be supplied with the New, Soft Start, Ignition system.
The numbers BEFORE that number "May" have been upgraded and could have either system.

Your engine has been treated like the proverbial Red-Headed-Stepchild, so it almost certainly needs the Old, Hard Start Stator.
The Current ED4(2018) Parts catalog is not going to help you.
They deleted the Legacy parts from the drawings.
I guess they figured that after 15 years, that is long enough.

Attached is an older ED3(2013) Parts catalog.

Look closely at Chapter 24-20-0, Pages 2,3 and 4.
And Chapter 74-20-00, Page 2,3,4, and 6.

EDIT:
The file is too big to attach. (10 MB)
Post your Email and I will send it to you directly.

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

Thank you said by: Dennis Urban

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Re: Stator replacement help

by Dennis Urban » 6 years ago

Dennis Urban

17 30 48

denniswurban@gmail.com

You are pointing me in the right direction.

I bet upon more research I will find that the standard stator bolts right in and works but needs the correct connectors. But I don't want to spend that much money first to find out.

And it might be difficult to locate the old stator PN, but I would like to know what it is (that old Parts catalog). I read in these posts that someone used an electric motor rebuild shop in Chicago for their stator. I prefer factory stuff, but I may have to look into that. There is such a shop near me in PA.

Mine is hard start (but always turns over easy, starts right away until now), not soft start, no sprag clutch.

Why does my stuff always end up being more difficult!
Thanks,
Dennis

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Re: Stator replacement help

by Bill Hertzel » 6 years ago

Bill Hertzel

13 1.95k 7.96k

denniswurban@gmail.com
Why does my stuff always end up being more difficult! ...

Your stator part number is likely on a label attached to your stator.
Of course, accessing the stator and the label is not an easy task.

An Old Wise man once said,
[quote]Once you open a can of worms, youré going to need to go buy a bigger can![/quote]

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

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Stator replacement help

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