Need help - Carryall ignition problems

Bay Devil

I have a 1996 Carry All with a history of electrical issues. A year ago I replaced all the wiring. Since a new harness was not available I rewired it in house and matched the wires exactly. Cart would not run correctly and eventually required me sending to a local CC dealer.

The dealer confirmed wiring was correctly done. They never could get the unit to operate with pedal start. Eventually they got the cart to operate with ignition on and once put into gear it would crank and then go. They had to tweak the micro switches a lot to even get it to this point. This lasted less than a year. Unit broke down and now only the starter/generator will power up.

My question is this:

Can all the micro switches be eliminated? I am OK with turning a key to start and turning a key to kill the engine? Can an ignition switch be installed that powers the starter long enough to crank the engine over and then the engine runs until killed with the ignition switch - just like starting a car? A much simpler electrical system?

My next option is just to do a big block conversion which would allow me to gut most of the existing electrical system and has a more simplified electrical harness.

BGW

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CP241

I've read your post, and frankly, having a hard time understanding why it would be so difficult. The electrical system is really very simple.

First, check and see if you have spark. I would bet not.

As for the wiring (just to explain)

One side of the key switch feeds power to the blue wire on the solenoid.

The other side of the key switch (white wire) feeds ground to the outer switch on the shifter so the cart only starts in gear. Goes out of that switch via green wire to the switch in the black box that activates when you press the pedal. Which goes out of that switch (orange wire) to the solenoid. This leg can only provide ground to the solenoid when 1. The shifter is in gear, and 2. The pedal is depressed.

If you press the pedal and the starter is spinning, all of the above is ok.



The other microswitch just provides ground out to kill the ignition coil when you release the pedal. If this switch sticks it can kill spark and the engine wont run.

There is a black/white wire next to the oil dipstick tube with a bullet connector. Disconnect it and see if you have spark. If so, then the limit switch has failed. If not, then plug it back in.

Theres a gold bracket with a little box on it. Theres a brown wire grounded to one of the bolts on that bracket. Disconnect it and make sure it's not touching metal. Try again. If you have spark now, then the rev limiter has failed. You can leave it unplugged and run the cart.

If still no spark then the ignition coil has failed.

You can also try a new spark plug. It's rare for a plug to fail completely (st least if jts a NGK) but possible.