Ignition problem

[Wheels]

My 80HP 912 Rotax had a mag check failure at run up.
First mag drop was almost nill, second mag was an erratic and rough running engine. Classic symptom of a module failure. I pulled the 4pin connectors and swapped them, no change. I pulled the ignition leads from the panel and swapped them and was able to swap the failure from mag 2 to mag 1. So I thought I had isolated the problem to the ignition wire from the panel/mag switch.
Figured this was the problem so I ran a new wire and bullet connector from the connection, test was negative. Did the same for the other bullet connector and still having the same issue. I did a continuity test on the switches and both checked out. could the switch be bad anyway? I'm now lost. Ideas?

[Av8r3400]

. I don't have good news for you. This is nearly the exact problem I was having.

Through process of elimination I was able to localize the issue to one ignition box. Replacing that one box with another from a good running plane did NOT fix the issue. I wound up replacing both boxes (with the new style and cheaper 6x6 pin) to get the problem fixed.

The full story:
http://www.teamkitfox.com/Forums/showthread.php?t=7119

[Wheels]

What did the new modules cost you. I am thinking of just parting out the engine and installing the brand new one I have one on stand by. I was going to change out in september anyway and I don't think this engine has any real value on the market
unless it is proven sound. I have had two electrical problems in a month and both related to its age. the wires just look old. So instead of spending time and money on the older motor, I can put in the new one and call it good and go fly. the parts alone on the old one should be worth most of the install costs. I really don't know what this thing is worth but nobody seems interested in it for the money I was asking. oops.
on the other hand, I need to fix the problem just to satisfy myself that I didn't waste 6 thousand plus dollars in training costs for all the schools I have attended since becoming a Rotax owner. I've kept it running for 5 years but most of the help came from this forum and rotaxowner.com. Honestly, all the experts live a few keystrokes away.

[jmodguy]

Been doing a little research on your issue and I found someone with an issue similar to yours. Their approach was to start the engine on 1 module only. L then right. If it starts on one and not the other then it becomes clear where the faulty module is.
As we discussed the other day, I really do not like bullet or other "rolled" contacts in such an extreme environment (engine compartment). That includes Molex and DB type conectors!

[Wheels]

I'll do that start trick in a few minutes. The new engine install will include moving the modules to the cockpit side of the firewall. I think slyfox did that and I saw it on another plane down in Corning California. In the meantime, I do want to fix this. Even if the engine goes for sale as a bush boat engine, it needs to work reliably for what it is.

[Av8r3400]

That engine will easily sell sans ignition. I'd buy it if you were closer. My module replacement project cost me in the neighborhood of $1500 with the conversion parts to the new style modules and plugs.

IMO, I would not put them through the firewall to inside the cabin. These modules and connectors are designed to be in the engine compartment environment. Adding a few inches to the wires to put them on the solid side of the engine mount is one thing, but inside the cabin is not needed.