---------------------------------------------------------- RotaxEngines-List Digest Archive --- Total Messages Posted Tue 08/24/10: 1 ---------------------------------------------------------- Today's Message Index: ---------------------- 1. 05:39 PM - Re: Re: Engine roughness Engine roughness (Hugh McKay) ________________________________ Message 1 _____________________________________ Time: 05:39:34 PM PST US From: "Hugh McKay" Subject: Re: RotaxEngines-List: Re: Engine roughness Engine roughness OK guys, Thom, Ron, Rick, Roger, Dick, Clive and others: I have found the problem and fixed it. I took all of your advice and counsel and went back again and began to systematically check each wire especially at or near the plug connectors on top of the engine. I went back and re-checked all the wiring one more time. This time I found a small break in the grey wire that goes into the A module coming from the connector to the red power wire coming up from the engine. I disconnected the plug and began to ohm the grey wire to ground. I got an open circuit. When I closely examined the crimped end of the connector on the end of the grey wire there were only a few strands of conductor that were not broke. Most were broke. I noticed also that the ends of the grey wires were not "tinned" before being crimped to the connector. They were just stripped and the connector plug crimped on the strands. This is very poor practice, and no wonder this type problem keeps showing up on these engines. Anyway, I cut the old connector completely off, "tinned" the bare ends of the brown wire and and the red wire, crimped on a new insulated male/female spade connector, secured everything and fired the engine up. Every thing is now working normal. She is "purring like a kitten"! Going flying tomorrow!! Thanks, Hugh McKay From: Clive Richards Sent: Sunday, August 22, 2010 5:00 PM Subject: Re: RotaxEngines-List: Re: Engine roughness Engine roughness Hugh I have only looked a while ago at an engine we have on the bench as plane is not built yet but think you will find the modals are Identical and as they are connected by plugs & Sockets you can swap them over. Our engine is an old one & has a different arrangement on the plugs to the current ones so if you need spares you need to get the correct one. >From your test the left module is faulty as when you kill the right module the engine stops Swap the P leads plugs at module end & if fault swaps moduals then switch or P lead is faulty. You previously mentioned disturbing a trigger coil lead if this lead has gone open circuit this will stop that module working as it fires 2 cylinders. I presume all was working ok originally but have you disturbed the plugs ? I notice from the manual that 2 plugs are fired at the same time by the ignition coils so a faulty open plug will stop the engine if that modual only is selected. do not archive Clive From: Hugh McKay To: rotaxengines-list@matronics.com Sent: Sunday, August 22, 2010 1:45 AM Subject: Re: RotaxEngines-List: Re: Engine roughness Engine roughness OK guys, We have checked all the wiring everyone has suggested for continuity: "P" leads, Kill Switches, wires to all the ignition pick-ups, and the two red wires going down to the engine (these two red wires are grounded in the engine per the Rotax 912 engine wiring diagram, so we just disconnected one end of each red wire on top of the engine and ohmed each wire to ground and we got continuity. Therefore we assume the red wires are good. We put everything back together and the engine did the exact same thing. The engine started and ran, but had a slight roughness to it. I ran it up to 2200 rpm and killed the left mag switch. There was no drop in rpm at 2200. The engine continued to run. I then opened the left mag switch and closed the right mag switch, and the engine died (was killed) immediately. Same problem!! Dick you suggested switching all the wires from one ignition module to the other. Are they identical and can they be switched without harming the engine? If we do this and the problem still occurs, but is on the other mag, what does this tell us? If the problem still occurs but is on the same mag, what does that tell us? Still searching, Hugh McKay Allegro 2000 ELSA Rotax 912 UL N661WW From: Catz631@aol.com Sent: Saturday, August 14, 2010 10:31 AM To: rotaxengines-list@matronics.com Subject: Re: RotaxEngines-List: Re: Engine roughnessEngine roughness Hugh, Something else you might try is switching wires from one module to the other and see if the problem follows. 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