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Ron Peach
Joined: 19 Sep 2020
Posts: 5
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 Posted: Sun Jun 22, 2025 12:53 am Post subject: How to replace 912uls starter motor |
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My starter motor has packed up. Suspected oil penetration. I need to replace it. I have a Europa Classic that I believe is XS firewall forward. The aircraft is stranded on an Island (IOW UK). I would like to tool up my car, catch a ferry and fix in situe (it is hangered with limited facilities).
From what I can see of the installed started motor it appears the be the standard type (short - 12cm from face to rear, black with internal threaded fixing rods/bolts).
I have two replacement starters available to me. One is identical to that fitted and the other appears to be the HD starter (it is 14cm from face to rear and has external threaded fixing rods/bolts).
I understand that the HD is unlikely to fit as it is too long. However if it did, the rods are wider apart. How would they bolt to the housing?
Most importantly - Can I change the starter motor with the engine in? If I have to pull the engine forward, can this be achieved with minimal disruption to exhaust, radiator, electricals etc? An engine hoist of sorts is available.
All help and advice gratefully recieved.
Regards Ron
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Burrilla
Joined: 25 Apr 2015
Posts: 188
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| Posted: Sun Jun 22, 2025 1:20 am Post subject: How to replace 912uls starter motor |
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I have changed my starter motor on my XS 912uls. It is fiddly but patience in undoing the bolts and manoeuvring. I have the HD starter.
If you have a starter motor that same as a replacement I’d go for that to make it easier to get you home where you can explore the second one.
I have the HD starter and the two bolts are the same spacing but if you are saying that the ones on yours are different then makes me suspicious what you have as they should be a direct replacement apart from length. The bolts on the HD starter are on the outside of the casing.
Alan
Sent from my iPad
| Quote: | On 22 Jun 2025, at 09:56, Ron Peach <ronpeach1(at)gmail.com> wrote:
My starter motor has packed up. Suspected oil penetration. I need to replace it. I have a Europa Classic that I believe is XS firewall forward. The aircraft is stranded on an Island (IOW UK). I would like to tool up my car, catch a ferry and fix in situe (it is hangered with limited facilities).
> From what I can see of the installed started motor it appears the be the standard type (short - 12cm from face to rear, black with internal threaded fixing rods/bolts).
I have two replacement starters available to me. One is identical to that fitted and the other appears to be the HD starter (it is 14cm from face to rear and has external threaded fixing rods/bolts).
I understand that the HD is unlikely to fit as it is too long. However if it did, the rods are wider apart. How would they bolt to the housing?
Most importantly - Can I change the starter motor with the engine in? If I have to pull the engine forward, can this be achieved with minimal disruption to exhaust, radiator, electricals etc? An engine hoist of sorts is available.
All help and advice gratefully recieved.
Regards Ron
Read this topic online here:
http://forums.matronics.com/viewtopic.php?p=515452#515452
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Davidcripps
Joined: 09 Aug 2021
Posts: 41
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| Posted: Sun Jun 22, 2025 3:18 am Post subject: How to replace 912uls starter motor |
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Ron
I am one of the Europa owners on the IOW (GBWJH). Do let me know if I can help. I am 10mins drive from Sandown and 15mins from Bembridge. Which one are you stranded at? I have plenty of aircraft tools and also know where I can get hold of an engine hoist if needed. I can also link you up with an inspector for anything that needs signing off.
Also happy to ferry fly you back home if you need or run you by car to the ferry.
Best way to reach me is by text or WhatsApp on 07393 761230. Happy to pop over to the airfield this afternoon.
Best regards
David
| Quote: | On 22 Jun 2025, at 10:00, Ron Peach <ronpeach1(at)gmail.com> wrote:
My starter motor has packed up. Suspected oil penetration. I need to replace it. I have a Europa Classic that I believe is XS firewall forward. The aircraft is stranded on an Island (IOW UK). I would like to tool up my car, catch a ferry and fix in situe (it is hangered with limited facilities).
> From what I can see of the installed started motor it appears the be the standard type (short - 12cm from face to rear, black with internal threaded fixing rods/bolts).
I have two replacement starters available to me. One is identical to that fitted and the other appears to be the HD starter (it is 14cm from face to rear and has external threaded fixing rods/bolts).
I understand that the HD is unlikely to fit as it is too long. However if it did, the rods are wider apart. How would they bolt to the housing?
Most importantly - Can I change the starter motor with the engine in? If I have to pull the engine forward, can this be achieved with minimal disruption to exhaust, radiator, electricals etc? An engine hoist of sorts is available.
All help and advice gratefully recieved.
Regards Ron
Read this topic online here:
http://forums.matronics.com/viewtopic.php?p=515452#515452
|
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JonathanMilbank
Joined: 14 Apr 2012
Posts: 395
Location: Aberdeen area
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| Posted: Mon Jun 23, 2025 2:01 am Post subject: Re: How to replace 912uls starter motor |
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Hand propping? I seem to recall that this has been done before. Several years ago I learned the hard way that one of my ignition circuits was live, while preforming the preflight gurgling/burping. Supposedly the engine must be cranking quite fast before the plugs "come alive", but I no longer believe that.
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erichdtrombley(at)juno.co
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| Posted: Mon Jun 23, 2025 6:01 am Post subject: How to replace 912uls starter motor |
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Hello Ron,
I just finished the job not two days ago. I have a 914 in a classic with the XS engine mount and standard starter. Download the heavy maintenance manual and read the procedure. Rotax do a good job of explaining the process. The illustrated parts catalog is also helpful to understand the assembly of the starter.
The job is really straight forward but access to the hold down clamp was challenging. I recommend removing the lower cowl to get better access to the head of the bolt on the hold down clamp.
My starter had been in place for over 25 years. Suggest applying penetrating oil to bolt if possible. Unfortunately, access to the head of the bolt precludes using a wrench or socket as the Rotax ring mount is in the way. I used the largest flat head screwdriver that fit in the slot which had a hex shaft to allow the application of a wrench. While pressing hard it keep the screwdriver engaged I was able to break the bolt free with by turning the shaft of the screwdriver with a wrench.
Next you will need to unbolt the exhaust bend at the cylinder head (13mm)to gain access to the two 8mm mounting nuts which secure the starter to the engine. I found that for the top nut on the exhaust a 12- point thin walled socket on a long extension worked really well. The bottom nut can only be removed with an open end wrench. The 8mm mounting nuts can be easily removed with a 12-point box end wrench. A 6-point box end will not work!
With the hold down clamp loose and the 8mm nuts removed carefully extract the starter from the engine keeping the starter together as an assembly. I used a flat blade screwdriver to gently pry it out of the engine case.
Do not just pull on starter or the body will separate from the bearing flanges. It’s the 8mm nuts that keep everything together.
Fish the starter out from the back of the engine mount.
Reverse the process to install new starter. The HD starter uses a different mounting arrangement and I can’t speak to the ease of installation. For the 912ULS the HD is preferred.
Good luck!
Erich Trombley
N28ET
Classic Monowheel 914
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budyerly@msn.com
Joined: 05 Oct 2019
Posts: 292
Location: Florida USA
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| Posted: Mon Jun 23, 2025 6:14 am Post subject: How to replace 912uls starter motor |
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Guys,
A good cleaning of a starter should be done between 5 and 10 years (but I never did it). The parts for a complete rebuild are only $100 USD and is not difficult. Some cleaner and new grease is all that is necessary. Clean the contacts with Scotch Brite re-lube and reinstall. The magnetic attraction on assembly is a pain but a few sticks of the proper size will allow you to move the starter parts into place. You learn quite a bit on a rebuild. Once complete, test your starter (securely hold it down of course) to be sure of your work.
In my case, I have a Classic trigear A054A with a 914. I have the XS firewall forward kit, so the installation of the new hi-torque starter was a breeze, well sort of. The high torque starter will start a 912/914 easily as RPM on a slightly discharged battery will still hit 500 RPM. I wrote about this some years ago.
Installation notes from memory:
I find removing the carb and tray under the carb to be a help. Don't fiddle with the throttle and choke cables, just lay the carb aside carefully. I remove the oil tank and set that aside also.
If memory serves (and it doesn't so well anymore) the starter nuts holding the housing come off the drive end for the installation. I use thin safety wire to hold the new starter housing securely in place during the installation until I have the starter fully seated and the nuts installed but not tight. Then cut the safety wire and pull up the nuts. Use Loctite on the nuts for trouble free operation. Remember, a loose starter will destroy your clutch.
Keep a magnet handy as it is needed to retrieve nuts and washers and such. It is a cramped and tight spot to work in. Even with the carb and oil can moved aside.
The Classic engine frame on the 80 or 100 horse 912 interferes with the installation of the hi-torque starter as it is longer and is not a recommended upgrade in my opinion, as modifications are needed to the frame for proper clearance. Frankly on the 80 HP 912 the high torque starter is not necessary unless in cold climates or with a weak battery. With anything electrical also check your wire connectors for looseness or corrosion and remove, repair or replace. You need good clean and tight connections on your starter wiring circuit.
Best Regards,
Bud Yerly
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Ron Peach
Joined: 19 Sep 2020
Posts: 5
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| Posted: Mon Jun 23, 2025 9:14 am Post subject: Re: How to replace 912uls starter motor |
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Thank you everyone for your responses. I have a clear mental picture of the task ahead. I will let you know how it goes!
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Area-51
Joined: 03 May 2021
Posts: 430
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| Posted: Wed Jun 25, 2025 10:53 pm Post subject: Re: How to replace 912uls starter motor |
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The standard low torque starter of the 80hp UL and 914 uses different mounting position holes in the crankcase. Less mucking around to fit what is already on there now and get home. High torque 912ULS starter motor will only fit a Classic frame with precise modification to the starter, and cannot be removed once the engine is installed. I am not sure the smaller UL starter can be removed insitu on a Classic frame without lots of foreign language and heavy breathing 👨✈️
If your aircraft has an intermediate frame between the engine frame and firewall frame then you have an XS setup, and it is easy to remove starter motor insitu.
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peterz(at)zutrasoft.com
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| Posted: Thu Jun 26, 2025 3:55 am Post subject: How to replace 912uls starter motor |
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And with an earthx batt the low torque spins the 912S like a champ, I’d dare say same or better than the high torque version
| Quote: | On Jun 26, 2025, at 3:07 AM, Area-51 <goldsteinindustrial(at)gmail.com> wrote:
The standard low torque starter of the 80hp UL and 914 uses different mounting position holes in the crankcase. Less mucking around to fit what is already on there now and get home. High torque 912ULS starter motor will only fit a Classic frame with precise modification to the starter, and cannot be removed once the engine is installed.
Read this topic online here:
http://forums.matronics.com/viewtopic.php?p=515461#515461
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http://www.matronics.com/Navigator?Europa-List |
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