Ignition Module Wires, Repair Advice
Hi, I have a 912 ULS with ~190 hrs (on a Kitfox IV on straight floats). Very close to the harness's plug for the ignition modules I found some bad wires, one that was broken under the coating, and a few others near breaking. The wires from the ignition modules are short to start with, not leaving much to work with. I have been going back and forth regarding the best way to fix this and am debating between the following choices;
1) Shortening all the wires to remove the portion closest to the plug and crimping on new terminals. This will remove the portion of the wires that were work-hardened during vibration of the connector, but result in a very short harness (which should be fine).
2) Cut all wires near the module, then use shrink wrap butt connectors to secure new longer wires (with terminals, and plugs). This should be secure, although 12 butt connectors so close together may make for a large bundle that will be vibration prone.
3) Cut all wires near the module, then solder on and very well secure new wires (with terminals, and plugs). I am not a big fan of this, as the solder joint could be a common point of failure in the future unless very well secured. I generally try to avoid soldering for aviation work.
4) Order new Rotax (Ducati) ignition modules. This is the least desirable option as the modules I have work just fine other than the poor wiring. The modules are not inexpensive to say the least.
5) Order new aftermarket ignition modules. I found an individual (Allistair Wilson) that sells new modules with the soft-start built in for ~$250 each. I have no idea if these are good quality and safe, although I did speak with him and he was very knowledgeable and helpful. But again, $500 for new modules vs ~$25 for new wire and connectors to fix my existing modules is a big difference if the outcome and safety is the same.
A last note on this, at the same time I will be moving the modules and coils to the solid portion of the engine mount to reduce vibration on them. This however has its own drawbacks, as now the wires from the trigger to the modules, along with the spark plug wires, must flex as the engine moves relative to the frame. Despite that, this is likely the way I will go to reduce vibration of the modules and coils themselves.
I know this is a fairly common problem, but I can't locate specific direction on solutions. If you could please lend your advice for items 1-5 above, or offer an alternative solution it would be great! Thanks in advance for the guidance with this, much appreciated!! Rick
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Originally Posted by RF47
