Revmaster CDI Ignition Issues and SOLUTIONS

[Matt541]

I already posted these in my project thread, but I wanted to make sure there was a separate reference topic for people searching in the "other" engines section.

Long story short, if you're having problems with your Revmaster CDI ignition system, be sure to check all of your connectors and wiring coming out of the CDI box. Then remove your CDI box itself and check ALL of the individual solder points and connections for condition. You can swap your coils around to different cylinders as well, but they're unlikely to be the problem.

Many thanks to the other Revmaster owners who helped me along the way!


I made these videos to help explain the process, and hopefully save you time. (Took me about 2 months, only getting to the airport once a week.)

Part 1: My Problems (Including isolating the Molex connectors from the circuit.)



Part 2: How I Fixed Them



Please let me know if you have any questions. I will also be posting a video about using the Seal All connectors from Aircraft Spruce, as well as a direct parts list needed for Revmasters.

[Matt541]

And here is the solution for the factory Molex connectors, or if anyone else is thinking about adding a top quality product to their build.

Delphi Weatherpack Connectors or in this case, the Seal-All brand sold by Aircraft Spruce.

Funny thing is, the connector shells say "Delphi" right on them, even though they're sold as "Seal-All."

It's a quality part, regardless of what name is on it

And now the list of tools and parts needed to ditch the Molex connectors.

Ready? Set. Go! (It's a long one.)

Seal-All Connectors:
Single- Qty 4 (Needed for ignition switches.)
https://www.aircraftspruce.com/catalog/ ... ectors.php

Double- Qty 12 (Needed for top of CDI box and each coil.
https://www.aircraftspruce.com/catalog/ ... ctors2.php

Seal-All Terminal Kits:
Qty 2 Sets 14-16 Ga
Qty 6 Sets 18-20 Ga
(Each set comes with 12 terminals, 6 male, 6 female.)
https://www.aircraftspruce.com/catalog/ ... ctors8.php

Seal-All Crimper Qty 1 (This has the correct ramp profile to draw the tabs in that typical crimpers don't.)
https://www.aircraftspruce.com/catalog/ ... tors10.php

Seal-All Pin Removal Tool Qty 1 (Easiest way to remove the terminals from connector if you need to make a change.
https://www.aircraftspruce.com/catalog/ ... tors12.php

Or both tools can be bought together from Amazon, but at the time it was cheaper to get everything from ACS:
Weatherpack Tool Kit: https://amzn.to/3pPJ1BJ

Also needed:
18 ga wire, plan on 20' of each color. 40' total.
(My circuit measurements below.)
This SHOULD be readily available at your local hardware store, but just in case , here's a set with multiple colors from Amazon:
https://amzn.to/335wznq
Multiple colors of electrical tape or heat shrink to color code the different circuits per the CDI diagram. (Again, should be locally available.)

Some kind of wire loom or sheathing to help protect the wires, I bought this stuff:
https://amzn.to/397jfmE
But you may be able to reuse the factory sheathing, I'm under the impression that what's used may vary from engine to engine.

You might need new rubber grommets where the wiring passes through the baffling, I did.

Alrighty then...

First cut your wires to the lengths needed after measuring your own engine and mounting pathways. But my measurements were:
(By circuit on diagram.)
Blue- 21" x 4
Red- 21" x 4
Yellow- 36" x 4
White- 36" x 4

(Actual measurements were 17-21" blue and red and 32-33" white and yellow, but I added some extra just in case.)

Next, follow the videos below.

The second video is the best way I found to double up the wires after the CDI box to companion cylinders.

Other than that, lemme know how you all make out and if you have any ?s.


Part 1:


Part 2:

[Matt541]

Forgot to mention, if you're thinking about doing this conversion, but don't want to buy extra tools you'll never touch again, shoot me a PM. Once I'm completely done with my project (any day now), I'm considering adding my tools to the Sonex Builders tool loan program. I've certainly benefited from it and I want to contribute as well. Cheers!