Part 03 Removing Cylinder 1 and 3 Inlet Manifold & Ignition Modules ...

Introduction ...

This page contains photos of removing the cylinder 1 and 3 inlet manifold and connected ignition system components from a ROTAX 912ULS engine (built August 2006).



ROTAX 912ULS Removing the earthing ignition cable from inlet maifold for cylinders 1 and 3

Image 1

Start by removing the three earthing (ignition system) cables from the inlet manifold for cylinders 1 and 3.

View Larger Image ...

ROTAX 912ULS Photos of ignition modules before dissaembly begins

Image 2

Here follows several photos of the existing ignition module installation mounted on top of the inlet manifold for cylinder 1 and 3. If you are disassembling this part of the 912 yourself it is handy to have several photos as a reference for rebuilding. Ultimatley the 912 IPC is the place to look for understanding how any 912 assembly goes back together but it doesn't do any harm to have photos to reference as well. This assembly wil get completley stripped down as part of the cleaning process.

View Larger Image ...

ROTAX 912ULS ducati ignition modules

Image 3

Note the position and orientation of the various P-clips etc ...

View Larger Image ...

ROTAX 912ULS ducati ignition modules

Image 4

Take as many different photos from as many different angles as possible!

View Larger Image ...

ROTAX 912ULS ducati ignition modules

Image 5

Note the Conair / Bully Hawk Soft Start module (top arrow) connector tied with a couple of cable ties along side the OEM SMD ignition modules. Bottom three arrow point to P-clips ...

View Larger Image ...

ROTAX 912ULS ducati ignition modules

Image 6

Note that there are a pair of 6-pin connector orientated horizontally and a pair below orientated vertically ...

View Larger Image ...

ROTAX 912ULS ducati ignition modules

Image 7

Note that the upper SMD is marked A and the lower module is marked B. Note also that the two digits of the year of manufacturer of the engine is only just visible on a label stuck to the upper surface of circuit A's SMD ...

View Larger Image ...



ROTAX 912ULS ducati ignition modules

Image 10

Here we can see the 6-pin connector going from ignition modules to ignition coils ...

View Larger Image ...

ROTAX 912ULS ducati ignition modules

Image 11

Disconnect the 4 lots of 6-pin to 6-pin connectors being careful not to pull directly on any of the wires themselves - always pull on the connectors themselves not the wires. There is a tab inside that must be released first and then the two halves of the connectors should slide apart with ease. If you are struggling to disconnect them then you haven't released the tab properly. A very fine flat blade screw driver is all that is needed to manipulate the tab into the correct position to release the connector.

View Larger Image ...















ROTAX 912ULS Conair soft Start modules

Image 26

The Conair Soft Start module that sits "piggy back" on the top of the other two SMD ignition modules shown here removed and on a parts tray ...

View Larger Image ...


ROTAX 912ULS ducati ignition modules exposed and disconnected

Image 28

The Ducati DCDI ignition modules exposed and disconnected. Note again the date of manufacture label. The last two digits are the year designator ...

View Larger Image ...

ROTAX 912ULS ducati ignition modules

Image 29

The lower set of two 6-pin connections can be seen here ...

View Larger Image ...

ROTAX 912ULS ducati ignition modules

Image 30

The first of the lower set of two connections disconnected and the upper SMD module removed leaving just the lower one still in place on the engine ...

View Larger Image ...

ROTAX 912ULS ducati ignition modules

Image 31

The upper SMD removed from the engine and on the parts tray ...

View Larger Image ...

ROTAX 912ULS ducati ignition modules

Image 32

The lower SMD still on the engine ...

View Larger Image ...

ROTAX 912ULS ducati ignition modules

Image 33

The lower SMD now disconnected and ready to remove ...

View Larger Image ...

ROTAX 912ULS ducati ignition modules on the bench

Image 34

Both of the ducati DCDI SMD ignition modules on the bench ...

View Larger Image ...

ROTAX 912ULS ducati ignition coils

Image 35

Remove the post with the ignition coils vibration mount ...

View Larger Image ...

ROTAX 912ULS ducati ignition coils

Image 36

The ignition coil set now has one further bolt securing it in place. Other than that the only thing now preventing this combined assembly from being removed is the spark plug leads with the lower plug caps ...

View Larger Image ...



ROTAX 912ULS lower spark plug cap removal

Image 39

Removal of the lower plug caps is necessary to slide the lower spark plug cables up through the gap between the cylinder barrels. Here you can see that they have been removed and the two HT leads and the red mechanical protection sleeve has already been pulled up and is now resting freely on top of the rocker covers. A piece of gaffer tape has been temporarily stuck on the end of the lower plug cables so that the yellow cylinder designator identifyers do not fall off the high tension cables - funtionality that was presviously provided by the spark plug caps ...

View Larger Image ...

ROTAX 912ULS ignition coil mounting post

Image 40

This ignition module retaining bolt needs to be removed and then the whole assembly should be free ...

View Larger Image ...


ROTAX 912ULS ignition coil set and manifold removed and on the bench

Image 42

Finally the manifold and ignition module on a parts tray ready for cleaning ...

View Larger Image ...


ROTAX 912ULS Free access to coolant system spider

Image 44

With both inlet manifolds and the ignition coil set and SMD's removed we now have access to the coolant spider ...

View Larger Image ...