Intermittent no spark - 1991 DS

junctioncitysd

I have a '91 DS that will run great when it's running. My problem is my cart runs well one day and the next day it will crank but won't fire. When it is running well, it starts well. My issue is I can't make the problem reproduce itself which leads me to believe it could be a bad ignitor, exciter or something else. I tested the spark when this is happening and there is nothing. One time it sparked for a second or two and quit again. It could be a short somewhere too.

I need some direction on how to trouble shoot this. I have a good handle on the location of all parts on the KF82 but I don't know the best way to test and find my problem. I think my solenoid is working well as the voltage goes from zero to about 11.5 V on the switched side when the accelerator is pressed.

Any help anyone can provide is appreciated.

Dale

BGW

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DRAGSHOVEL

I helped a friend with his 91 and his intermittent spark was due to the plug wire off the coil. It was grounding out and causing no spark to the plug. We replaced it and it's been fine.

junctioncitysd

Dragshovel - Did you replace the entire ignitor?

DRAGSHOVEL

If your looking to buy a new one then yes that's the only way they service the plug wire. I happen to be a parts manager and still had a roll of 7mm plug wire. We made our own for next to nothing.

junctioncitysd

Does the plug wire eventually ground out due to the insulation wearing thin in places or the does the wire actually break? I'm wondering if this isn't my problem as I made it spark when I put a pair of vice grips in the plug end and moved the wire while cranking. It's also very intermittent as it will run fine one day and not fire the next.

DRAGSHOVEL

In my case the wire was grounding out through the insulation.

DRAGSHOVEL

We were able to wiggle the wire while still hooked to the spark plug and could see spark to ground halfway down the wire.

junctioncitysd

Thanks for the information. I just ordered an igniter. I'll keep you posted when I have it installed.

DRAGSHOVEL

Good luck. I hope it gets you running again

junctioncitysd

Update - I installed igniter. It sparked much better but still didn't run. I dug deeper and tore apart fuel system including carb. My needle off the float was stuck shut I think. It is running well now but I may be looking at new carb or kit in the future. I ordered a new Holdwell fuel pump off amazon. I'm going to install it and keep old one for back up. I also redid all fuel lines and filters. I think the fuel filter was original. Not good.

Word of advice - I avoided taking the body off to work on my cart before now. Find the parts manual online for your cart and just remove the body. It makes everything so easy to work on and you can see all the built up dirt hiding under stuff that should be cleaned. It is only six to eight bolts for the body and a few more for canopies, club holder etc but still worth it.