912UL Ignition - 4 Pin to 6 Pin

[drwalker57]

I've been chasing an intermittent ignition issue down for days and finally decided to replaced stator, trigger coils, and CDI Ignition boxes - they are all quite old, worn with lots of frayed and cracked wires. Even the Ohm readings are intermittent, though usually grounded out. In process of the replacements, I would like to convert the 4Pin connectors to a six Pin configuration. Can someone point me to a source and enlighten what else I might need to do.

Thanks for your kind assistance.

David Walker

[Av8r3400]

Download the Heavy Maintenance Manual (https://www.rotax-owner.com/pdf/MMH_912_914_Ed2.pdf) for the wiring diagrams.

I converted my mid 90s vintage 912UL (with Zipper Big Bore) to the new style 6x6 ignition boxes with the soft start feature. I needed to replace the original boxes and they had a lead time in the range of years...


Read through this thread for what I did including a parts list. https://teamkitfox.com/Forums/thread...light=ignition

[drwalker57]

Thanks for that information, I've studied the HMM and ordered most of those parts already. I am a bit confused about these two items 12 - 265-210 Connector Pins and
12 - 265-275 Connector Sockets. The lead wires from the stator have connector pins already as do the trigger coils. Do I cut those off in favor of the ones you have specified, or are they the same thing?

[Av8r3400]

Thanks for that information, I've studied the HMM and ordered most of those parts already. I am a bit confused about these two items 12 - 265-210 Connector Pins and
12 - 265-275 Connector Sockets. The lead wires from the stator have connector pins already as do the trigger coils. Do I cut those off in favor of the ones you have specified, or are they the same thing?

I relocated the ignition boxes onto the engine mount therefore needed to extend the wires. That and the fact that I was converting from a 4 pin system meant I rewired the entire system.