1. In line with the mechanical sync protocol when I loosen the nut (4) retaining the throttle cable the throttle arm reliably is pulled to the stop. But the cable is a bit long, so that if I tighten the retaining nut while the cable is slack and the throttle arm is sitting on the stop I end up with a bulge in the cable. While the install manual does not offer specific guidance about what to do with the slack, the paraphrase is that you should have lots of cable lying around. So I have taken up the slack to where the cable is firm, but not taught, and the throttle arm is on the stop. Correct?
Your #1 question can be normal with your bulge (extra cable) when the throttle is fully open. You want the throttle to be fully closed and fully open at those respective positions during your mechanical sync and throttle position check. Rotax does have specific hose for the comp tube that is a very tight friction fit.
Roger Lee LSRM-A & Rotax Instructor & Rotax IRC Tucson, AZ Ryan Airfield (KRYN) 520-349-7056 Cell
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