94 gas CC

Unworthy

I have a 94 gas cc ds that has a spark issue. Sometimes it won't start and sometimes it'll die for no reason, when the problem occurs I can pull the plug wire and there will be no spark, I can stick a screw driver in the plug wire and ground it out while pressing the accelerator and it might take 30 seconds of doing so or it might take 3 mins but it will regain spark, it might run for 5 mins or 2 hours but it will do it again. I changed the coil and it worked fine for about an hour then it went back to its old problem. I also replaced the 2 micro switches on the back of the gear selector since I could tap on em and regain the spark but that didn't help. I know there are lots of things it could be but don't know how to test everything. I have a few disabilities that keep me from hanging upside down in the motor compartment for very long. I'm really hoping for a simple solution but I will happily try whatever I need to.
Thank for taking a min to help a newbie out.

BGW

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R1D2

I may be the least knowledgeable. And I am not there to see it. But could it be the plug wire?

lockman1

Another possibility is a failing rev limiter!

invalidsession

There are two more micro switches in the black box near the battery. These are a common failure point and as Lockman suggested, the rev limiter can have issues as well. Remove the ground wire from the limiter and you will have eliminated that area, the switches will need to be replaced though.

Chris.

Unworthy

The plug wire is new but the end and boot are not so I'll look into getting one.

Where is the rev limiter and what does it look like?

Also I will order the 2 micro switches and replace them.


Thank y'all for the help

invalidsession

The rev limiter is located just to left and under the the cylinder as you look back from the foot well. A mirror helps since the sadistic bastards at Kawasaki have tucked it conveniently out of view.

Chris.

Unworthy

Thank you Chris, I've seen it down there with a few wires running to it but didn't know what it was. I'll mess with it tomorrow and post the results

invalidsession

The ground wire is braided with about 1 inch of the braid showing off the connection point. If you are confident, just rock it back and forth and snap it off. It's easier than busting your knuckles with a spanner. It'll be on the left lower side of the limiter when viewed from the front of the cart. I usually just put a piece of shrink tube on the wire but electrical tape will do and the odds that it accidentally contacts it's old host is remote. I can field fix this issue in under a minute.


Chris.

Unworthy

I checked the plug wire and micro switchs, they were good. Next I unhooked the rev limiter ground and no more problems!! So now my question is, does the cart need the ground? Should I order another rev limiter or just roll like it is?

invalidsession

Drive it like you stole it. Do you still have the axle limiter in place ?


Chris.