I had a similar problem with one of my springs, it and broke four times in 100 hours.
I meassured the distance between the loops holding the springs and found that the distance where the spring kept braking was greater than the rest. I fitted a slightly longer spring and that solved the problem.
I still tie locking wire down the centre of the springs just in case one beaks.
Everyone should safety wire their exhaust springs. Use the heavier .040 safety wire and do not try to wire it tight. It needs to move so leave it just a tad loose.
Roger Lee LSRM-A & Rotax Instructor & Rotax IRC Tucson, AZ Ryan Airfield (KRYN) 520-349-7056 Cell
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