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Hi,

I have a 2002 Rotax ULS engine with just under 700 hours. Carbs are balanced, no soft start, and I have the older black starter motor. I’ve flown 100 hours with the aircraft and it’s always been a bit of a git to start, although better since I upgraded the battery and battery cables.

My symptoms are that full choke results in juddering when trying to start with the propellor stopping, then starting again (kickback?)
If I try to start without choke but with half throttle, the prop will just spin but there’s no juddering or kickback.
When it’s not very cold (sub 5°c), having mags off but full choke on and starting for ten seconds, followed by no choke and mags on plus starting will result in immediate start. Cold starts result in the struggling start.

I suspect the sprag clutch it just wanted to pick your brains before getting someone in to check.

Cheers in advance
  • Re: Rotax 912 2002 model starting issues

    by » 5 years ago


    This is the same problem a Rans Coyote II had in my shop right now. A better battery and the high torque starter fixed that. Cranks right over now. The black starter gave me issues back in 2003 on an old plane I had. Changed to a better battery and the gold colored high torque starter and cold start issues disappeared.
    If you have prop kickback where it starts forward, but slams back in the opposite direction you need stop and not keep doing that or it will absolutely ruin your starter sprag clutch. I don't know what your idle is set at, but most of the time I tell guys to crack the throttle and full choke the first start of the day. Many guys have come in and complained about a hard start (with high torque starter) and I get them to start cracking the throttle and their hard starts go away. The start up rpms tend to be right around 2200-2400. Where you have the idle set plays a part here. If idle is already at 2K then don't mess with the throttle, but if it's 1800 and below crack the throttle. It can make all the difference.

    Just try it and see if it helps, but a new high torque starter is probably in your future.

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


    Thank you said by: James Llewellyn

  • Re: Rotax 912 2002 model starting issues

    by » 5 years ago


    Thanks for the quick reply. The better starter was on the “to get list” in any case! Glad to know you’ve seen the same symptoms. Thanks again

  • Re: Rotax 912 2002 model starting issues

    by » 5 years ago


    Just to update with regards to the black and gold starter motor sizes.

    Ordered the heavy duty starter from Rotax. It measures 160mm compared to the 120mm standard black starter.

    Fortunately, the new gold coloured starter has a couple of lugs on the end which are easily removable and reduce the starter length to 130mm (could possibly shave more off but it’s not necessary for me).

    Not fitted yet, however hoping to do so on Monday once the winds die down. Fingers crossed it results in better starts!

  • Re: Rotax 912 2002 model starting issues

    by » 5 years ago


    You'll like the difference with the newer gold high torque starter over the older black one.

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


  • Re: Rotax 912 2002 model starting issues

    by » 5 years ago


    Just a quick update!

    A bit delayed in fitting due to work, however after losing a lot of blood and fighting exhaust springs, she works!

    The difference is frightening, makes me realise how much the black starter had been struggling. I carried out a test turn before replacing the cowling/exhaust to make sure it was a actually working. “More grunt” is an understatement!!

    For anyone else doing the same upgrade...

    The black starter is held in by 5/8” nuts (again, caused me a delay in having to buy the correct wrench/spanner) the gold starter uses 7mm nuts.

    The bracket from the black fits the gold model, and I had to use that as the new bracket was slightly too tight (I also had to reverse the orientation of the bracket to suit my setup). The bolts hold the whole assembly together, so exercise caution if undoing them!

    Now starts like a proper rotax!

    Thanks very much for the advice Roger :)

    Thank you said by: RotaxOwner Admin

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