Hey Rich! It is likely that one of the mag ground wires is not grounding
properly when switched off. If you are using the typical ACS type switch
(Cessna type) the connections on that unit are confusing. Several builders
have had problems identifying the proper terminals on the back of the switc
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resulting in exactly what you describe. Use an ohm meter to verify proper
grounding.
BTW the Rotax will not ignite if cranking RPM is below 220. Just the same,
be very careful if hand turning the propeller when any ignition module is
still =B3hot=B2 (not grounded).
kp
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