Marco01 Posted August 5, 2013 Report Share Posted August 5, 2013 Just would like to add my inputs on Rotax no start from this side of the Atlantic. My CTSW/100 ps Rotax/2007/800 hours has refuses to start for 2 weeks, not even a small evidence that, at least, sparks plug got something. Listening mechanical and other friends, I tried: - looking at a Spark on spark plug: nothing, even on a dark room. - recharge the battery: not better. - check the fuel if any contamination in the filter, or in the bowl carb: nothing (bowl full, no water, no contamination) - checking ignition key if on 1+2 position is not grounded: Ok - checking impedance from all generator coil: Ok( I compare it with an other Rotax dismounted) - replace the Regulator by a new one: no improvement. - check grounding connection: nothing was looking bad. Finnaly, one person in a shop give me this adivce: with all your test, your engine should work! Stop to touch everything, set your engine in best condition for a good start, and try again. So, back to the airfield and it finnaly starts with the following: - listen Roger witch is strongly pushing on grounding: I have clean and tight all grounding bolt. Changed the one with spot of corrosion. -fully charge the battery again (with an advanced digital charger) 3 A/H was missing. - replace all spark plus by new ones (not done on the last 200 hours) - let run some fuel out. -ignition for 10 s.: nothing (bowl carb. Were empty) - try #2: almost started! (large smile) - try #3: started : flew arround the pattern (on safe altitude): everything worked fine to allow nice local flight in Burgundy) Conclusion: -read and execute Roger's advices! Thanks again for your inputs: no one got your level here! Engine did not start due to a component failure, but due to the addition of several "weakeness" as battery partially discharge, old spark plugs, high air temperature, some grounding not 100% perfect and probably poor fuel quality. Hope this helps.... Link to comment Share on other sites More sharing options...
CT2kflyer Posted August 6, 2013 Report Share Posted August 6, 2013 Welcome to the Blog........... Link to comment Share on other sites More sharing options...
N89WD Posted August 6, 2013 Report Share Posted August 6, 2013 Hi Marco01....France, land of my not so distant ancestors. We are fortunate to have Roger in our midst. He is most knowledgeable! Many others are as well. You'll find them as you frequent the site. Glad your bird is up and flying. Link to comment Share on other sites More sharing options...
Roger Lee Posted August 6, 2013 Report Share Posted August 6, 2013 Those kind of problems and trying to find that ghost can sure make you want to bang your head against the wall. Glad it worked out. Link to comment Share on other sites More sharing options...
opticsguy Posted August 7, 2013 Report Share Posted August 7, 2013 I suggest replacing your ignition modules. Your problem was exactly like mine. There was an issue with late 2006 and maybe early 2007 ignition modules. Since I replaced mine, the starting problem that I had for 3 years went away. Link to comment Share on other sites More sharing options...
Roger Lee Posted August 7, 2013 Report Share Posted August 7, 2013 There certainly have been a few modules go bad and any unexplained starting issue they should at least be considered, but for the most part they hold up pretty well. Link to comment Share on other sites More sharing options...
tennesseect Posted August 14, 2013 Report Share Posted August 14, 2013 I'm having similar starting problems - after not being run for 12 days I get no spark at the plugs. Am I understanding correctly that the eventual fix was to do the following 3 things: 1) replace the plugs 2) check starter switch connections and 3) tighten all ground connections ??? Link to comment Share on other sites More sharing options...
Roger Lee Posted August 15, 2013 Report Share Posted August 15, 2013 Check the grounding wires for the starter switch, The the two red wires up at the ignition modules 6 pin connectors, then place an ice bag on the starter modules for 15 minutes and then try it. If it starts buy two new starter modules. I'm serious. Link to comment Share on other sites More sharing options...
tennesseect Posted August 15, 2013 Report Share Posted August 15, 2013 Roger, what / where are the "starter modules" I should put ice on? I should mention that my CT was flooded in the hangar 3 years ago - makes me suspect corrosion on ground lugs. Link to comment Share on other sites More sharing options...
tennesseect Posted August 15, 2013 Report Share Posted August 15, 2013 Roger, where can I get a wiring diagram for the starter switch showing which connectors should be strapped to ground? Link to comment Share on other sites More sharing options...
Roger Lee Posted August 15, 2013 Report Share Posted August 15, 2013 The ignition modules are on top of the engine. They are those two small black boxes on the right side. Put the ice right on top and let it sit for 15 minutes to really cool the modules. the colder the better. Heavy Maint. manual. Section 74-00-00 page 33 Link to comment Share on other sites More sharing options...
Marco01 Posted August 15, 2013 Author Report Share Posted August 15, 2013 Opticsguy and Roger, I'm thinking of replacing the module if this happen again. Price is arround 1000$ for one module: painfull... I have also heard that new modules could be fitted with a soft start facilities embedded. I will consider this as well. Ice on the module is a good trick I will try next time since those issues happen when external temperature is higher than 32 degrees Celcius. I will keep you posted... Link to comment Share on other sites More sharing options...
Roger Lee Posted August 15, 2013 Report Share Posted August 15, 2013 Right now two new Rotax soft start modules are around $900 for the pair, but won't stay forever. I heard they may go back up soon, but who knows until it happens. Link to comment Share on other sites More sharing options...
tennesseect Posted August 16, 2013 Report Share Posted August 16, 2013 THANK YOU SO MUCH, ROGER! Just like you said - my CT cranked right up after cooling the ignition modules with ice. You're a damn jewel! Link to comment Share on other sites More sharing options...
Roger Lee Posted August 16, 2013 Report Share Posted August 16, 2013 Glad it worked out and you now know your problem and how to fix it. But it's like batteries, documentation is not included. LOL Link to comment Share on other sites More sharing options...
opticsguy Posted August 17, 2013 Report Share Posted August 17, 2013 I ate the cost of the modules. A $128,000 plane that won't start is worthless. Haven't had a problem since then. Lockwood is up to speed on this issue, but Rotax is pretending it doesn't exist. Link to comment Share on other sites More sharing options...
Roger Lee Posted August 18, 2013 Report Share Posted August 18, 2013 Anytime something goes wrong with your Rotax you must send in an SIR report or they will never have any clue as to the size of a problem or how common it might be. Link to comment Share on other sites More sharing options...
opticsguy Posted August 18, 2013 Report Share Posted August 18, 2013 Did that going on 2 years ago. Sent it to Lockwood, that is. Link to comment Share on other sites More sharing options...
Roger Lee Posted August 18, 2013 Report Share Posted August 18, 2013 Anyone that has a warranty issue or a major failure of a component should go to www.rotaxflyingclub.com and fill out the SIR (Service Information Report) right on the site. These people are the only ones that can help you. You can send it through the distributors, but sometimes it gets lost in the mail.If you have not heard back from someone in 30 days follow up. Link to comment Share on other sites More sharing options...
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