91 ezo textron robin ec25-3pg very weak spark

jimmyjamez1212

I have searched other threads with no luck. I have replaced EVERYTHING in the ignition system. I still have very weak spark. I have a spark tester with an adjustable gap. Will spark when the gap is almost closed. At the solenoid wire from the pedal switch, I have 12 volts. When that wire is conected to new solnoid, it drops to 8 volts. At the red wire to the solenoid is also 8 volts. btw this is when cranking. At the wires on the generator I also have 8 volts. I cannot for the life of me figure out why I have such a high draw. I am blaming this low voltage for the super weak spark. Any other ideas? I have cleaned every connector on the machine as well. Thanks

BGW

__________________
This advertising will not be shown in this way to registered members.
Register your free account today and become a member on Buggies Gone Wild Golf Cart Forum

Cartmaster

Has a load test been done to prove the battery is good? Try jumping the battery from another vehicle and see what happens. If the battery is poor, then cranking will definitely produce a poor spark. You should only see a drop down to 10/11 volts when cranking. When you say you replaced everything on the ignition system, you did not include the battery. This is the most important part LOL. If battery is bad, then so will the rest of the system be.

jimmyjamez1212

Because of the excessive cranking I do, I constantly have a jump box to the battery. This morning I started doing voltage tests at the forward reverse switch. Let me back up. At the solenoid, starter motor wire disconnected, I get 12+ volts. Connected I get 8v. So I started checking at the back of forward reverse switch. If i dissconect the hot wire that puts voltage to the switch I have 12v. Connected I lose down to 8. Then I disconnect it and removed the other hot wire going back to the motor. I have 12v going through the f/r switch to the stud. Reconnect the wire going back to the motor and see 8 again. I am believing that the starter motor could be dirty inside and causing such a voltage drop. This is where I am unsure. Also, I am only working with the older 89/90 wiring diagram. I am unable to locate the newer 1990/91 diagram to make sure wires are indeed even hooked up properly before this thing came into my possesion.

jimmyjamez1212

Update. Also only 8v coming out of green wire from the generator.

Cartmaster

HMMM. does sound like maybe a dodgy starter/generator. I think, there may be some info on how to test the starter/gen here somewhere. i will see if i can find it.

jimmyjamez1212

Id appreciate that cartmaster. This thing has my brain hurting!

Cartmaster

Its taking me a while to find anything, its been ten years since i was last here LOL. someone will pop in shortly with answers, i am sure. But bear with me. I have all the service manuals in PDF form somewhere too. looks like i will need to dig them out.

Cartmaster

I have found an 89 to 93 service manual in PDF. Will that help? If so pm me your email address and i will mail it to you.

jimmyjamez1212

I found the manual. Thanks! Time for some generator testing. And for your amuzement..... I thought i would supply my own voltage to the regulator... now ordering a new one lol

jimmyjamez1212

field coils are grounding inside the generator. Im just happy I finally figured it out.