Rotax 912is Fuse Box Gray Plug

[P Johnson]

A friend of mine had this happen to his Rotax 912is installed in a A32 Vixxen aircraft, it could have been due to location of the fuse box in that airframe but I wondered if anyone else had suffered this problem in a Kitfox? There is a Rotax SI that recommends the changing of the gray plugs for the heavy duty metal ones that are now fitted on the 915/916 engines.

SI-912 i-024_SI-915 i-006_Introduction of a new connector for regulator B for ROTAX Engine Type 912 i, 915 i A and 915 i B (Series).p

dfWhatsApp Image 2025-03-27 at 13.29.44.jpgWhatsApp Image 2025-03-27 at 13.29.44.jpg

[Eric Page]

Rotax really screwed up when they installed those Deutsch DT series connectors on the 912iS and 915iS. They're rated for 13A per contact, and they run right at the limit. I have no idea why they made the SI optional for the 912iS.

The Rotax-specified connector set (an Amphenol "ecomate RM") is about $460 from a Rotax dealer (see item 32, here). You can buy the exact same connector parts from Mouser for about $71, here. Tooling for these connectors' contacts is not cheap; see here and here -or- here and here.

If that's an Experimental aircraft and you want to do the repair at lower cost, consider using Amphenol ATP connectors instead. They're an exact copy of the Deutsch DTP (big brother to the DT that Rotax used) at barely more than half the cost. They can carry 25A per contact; more than enough for this application. A good quality crimper is cheap. Amphenol ATP parts for this repair are here. The genuine Amphenol crimper is the last item on that list (hint: it's the same tool with blue handles).

---

P.S. If you want tooling for all three sizes of connector (Deutsch DTM, DT, DTP / Amphenol ATM, AT, ATP), here you go:

DTM / ATM: Amphenol AUTK-20 -or- iCrimp IWD-20

DT / AT: Amphenol AUTK-16 -or- iCrimp IWD-16

DTP / ATP: Amphenol AUTK-12 -or- iCrimp IWD-12

[ADK-Flyer]

Rotax really screwed up when they installed those Deutsch DT series connectors on the 912iS and 915iS. They're rated for 13A per contact, and they run right at the limit. I have no idea why they made the SI optional for the 912iS.

The Rotax-specified connector set (an Amphenol "ecomate RM") is about $460 from a Rotax dealer (see item 32, here). You can buy the exact same connector parts from Mouser for about $71, here. Tooling for these connectors' contacts is not cheap; see here and here -or- here and here.

If that's an Experimental aircraft and you want to do the repair at lower cost, consider using Amphenol ATP connectors instead. They're an exact copy of the Deutsch DTP (big brother to the DT that Rotax used) at barely more than half the cost. They can carry 25A per contact; more than enough for this application. A good quality crimper is cheap. Amphenol ATP parts for this repair are here. The genuine Amphenol crimper is the last item on that list (hint: it's the same tool with blue handles).

---

P.S. If you want tooling for all three sizes of connector (Deutsch DTM, DT, DTP / Amphenol ATM, AT, ATP), here you go:

DTM / ATM: Amphenol AUTK-20 -or- iCrimp IWD-20

DT / AT: Amphenol AUTK-16 -or- iCrimp IWD-16

DTP / ATP: Amphenol AUTK-12 -or- iCrimp IWD-12

Did you change these plugs out on your engine? This is the first I've heard of this issue. It wasn't in the SB's or ASB's and I've never seen any other instances of this happening.

[Eric Page]

Did you change these plugs out on your engine?

I haven't yet. My engine is still in the crate, but it is on the affected list and it has the offending Deutsch DT connectors.

[ADK-Flyer]

I haven't yet. My engine is still in the crate, but it is on the affected list and it has the offending Deutsch DT connectors.

I'm glad I saw this thread so I can replace the connectors before installing my engine.

[P Johnson]

Thank you for the comments. As it is not mandatory to change the grey (English) plug, and at this time there have been no grey plugs problems being reported in Kitfox airframes along with the ease of which the plug can be inspected both visually and physically through the oil filler door I will take up a regime of monitoring.

[ADK-Flyer]

Rotax really screwed up when they installed those Deutsch DT series connectors on the 912iS and 915iS. They're rated for 13A per contact, and they run right at the limit. I have no idea why they made the SI optional for the 912iS.

The Rotax-specified connector set (an Amphenol "ecomate RM") is about $460 from a Rotax dealer (see item 32, here). You can buy the exact same connector parts from Mouser for about $71, here. Tooling for these connectors' contacts is not cheap; see here and here -or- here and here.

If that's an Experimental aircraft and you want to do the repair at lower cost, consider using Amphenol ATP connectors instead. They're an exact copy of the Deutsch DTP (big brother to the DT that Rotax used) at barely more than half the cost. They can carry 25A per contact; more than enough for this application. A good quality crimper is cheap. Amphenol ATP parts for this repair are here. The genuine Amphenol crimper is the last item on that list (hint: it's the same tool with blue handles).

---

P.S. If you want tooling for all three sizes of connector (Deutsch DTM, DT, DTP / Amphenol ATM, AT, ATP), here you go:

DTM / ATM: Amphenol AUTK-20 -or- iCrimp IWD-20

DT / AT: Amphenol AUTK-16 -or- iCrimp IWD-16

DTP / ATP: Amphenol AUTK-12 -or- iCrimp IWD-12

Just a heads up I ordered the cart you created for the actual Amphenol plugs Rotax uses and this part you had listed 654-RT06164PNHEC is the wrong part as you added 2 male plugs to your cart. It's supposed to be 654-RT06164SNHEC which is the female version of the engine side plug. I got them in and struggled trying to plug them together before I realized something wasn't right. When I looked at the PDF from Rotax I could tell the end looked different. I wanted to update this before anyone else ordered them because I believe once you open them there's no returns and the one fitting costs $40 with shipping. I should have read the data sheets for the fittings better I guess before I ordered the cart. I've also attached the pdf for replacing the connectors from Rotax. si-912i-024.pdf

Amphenol pic 7.jpgAmphenol pic 6.pngAmphenol pic 1.jpg

[Eric Page]

Oh no! I'm very sorry about that. I've updated the list at Mouser to reflect the correct part number. Thank you for posting this; hopefully you've prevented anyone else from having the same problem. Again, my apologies!

Updated link: https://www.mouser.com/Tools/Project...sID=ee2b6c0ab3

---

I wish I could edit my original post above, but the forum doesn't allow it. Even if it did, I couldn't edit the other two users' posts that quoted mine. Hopefully future readers will continue down the thread before ordering. I've deleted the old cart three times at Mouser but the old link still brings up the same incorrect part list. Aaargh!

[ADK-Flyer]

Oh no! I'm very sorry about that. I've updated the list at Mouser to reflect the correct part number. Thank you for posting this; hopefully you've prevented anyone else from having the same problem. Again, my apologies!

Updated link: https://www.mouser.com/Tools/Project...sID=ee2b6c0ab3

---

I wish I could edit my original post above, but the forum doesn't allow it. Even if it did, I couldn't edit the other two users' posts that quoted mine. Hopefully future readers will continue down the thread before ordering. I've deleted the old cart three times at Mouser but the old link still brings up the same incorrect part list. Aaargh!

I received the other connector and the second one I ordered was indeed the right one. Don't worry about it by the way I should have read the fine print as both say female in the description. I ended up filing for a return on the connector and was honest that I ordered the wrong one and Mouser refunded my money for the wrong connector and told me to keep the original as well so all is well. Thanks