weak spark issue

bajamanjc

I get one spark when the solenoid first gives power to the starter then no spark while the engine is turning over. When I let off the gas I get one spark again before the engine stops.

Anyone know why I'm not getting a spark for every rotation of the motor?

BGW

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BrewCityMusic

A couple of questions:

What year and model is the cart?
What's the battery voltage before you turn it over (sitting)

That'll give us at least a starting point to help you out!

bajamanjc

1987 exgo gas not sure on the other details (marithon?)

12.7 volts before starting
tried a little bit to start the cart and still at 12.6 volts holds a good charge

thanks for any help, Shouldn't I get a spark for every rotation?

BrewCityMusic

Yes you should ... First, I know it sounds obvious but did you thoroughly check all the connections from the battery? There are 2 ground points that are very important and very often go bad and cause your symptoms - first, pull the ground connection at the frame (the first stop the ground wire takes from your battery). Wire brush or lightly sand both the connector and the frame tab, if the bolt is rusted, replace it. Next, unbolt the long bolt that connects the ground strap to the motor and do the same, making sure the connection is 100% clean and tight (if it isn't, the spark plug has a positive charge coming from the coil but will be looking for a ground, and will generally find an intermittent one through the throttle cable, choke cable, etc) ...

If that fails, check the spark plug wire for damage or that it's not laying against grounded metal, if that's OK then move onto the coil. Put a DMM across the 2 wires going to it and turn the cart over, you should be getting right around 12vdc (if the reading is weak or intermittent there, then we'll start tracing it back to figure out where it's problematic, but many simple "no spark" or as in your case "intermittent spark" situations are fixed by doing the above)

Let us know what you find, and we'll go from there if you're still not sparking correctly. Guys, please chime in with anything I may be overlooking along the way here!

chardonite

A one spark situation like he is talking about is usually the igniter.

Phillip

My 89 did the same thing. I put in an HEI, and solved that problem.

bajamanjc

I checked today and battery cables are grounded nice with no corrosion/rust and tight. Plugs wire is also in good shape. I tested the solenoid and it is sending 11.5 volts to the coil and looks like the wire is pumping out a strong current to the plug.

i am at a loss here. Tonight I only got a spark when I let off the gas and only one spark at that. Where is this igniter thing and how do you test it????

Tell me more about where to get a HEi (coil?)

BrewCityMusic

The HEI is a simple conversion, fairly low-cost, and generally solves any ignitor problems, as it eliminates the factory ignitor entirely (which is a good thing, as the factory ones are next to impossible to find, and when you can are usually over $100).

First, pick up an HEI Ignition Module for a 1976 Chevy 350, it'll run you right around $20-ish online, or 30-ish at a parts store. Brand is irrelevant, I have an Accel in mine but the stock GM one is OK too (they all do the same thing).

Second, find a spot on the frame (I mounted mine right by the battery) and scrape / wire wheel all the paint off in a spot approximately the size of the module. This serves 2 purposes, number one it provides an excellent heatsink as these modules throw a TON of heat for their size, secondly it ensures a solid ground between the frame and the rear of the HEI module. Mount the module solidly on the frame (I used #6 through-bolts but good self-tappers will also work) - here's a terrible pic for reference:



Once you're all mounted up, here's the wiring schematic - the wires you will need to cut and extend to the HEI are coincidentally the ones that are currently hooked to your ignitor, so it's a lot easier than it looks.



Once you're all wired up, double check to ensure you have a good ground to the mounting bolt (as shown in diagram) as well as the rear of the HEI module, then go ahead and fire up the cart. If it runs like it should, you're done - if on the other hand it runs but has no power and seems to limit the RPM's by itself (which is common) then go ahead and swap the red and blue wires around (the ones from the pulsar) - that should fix it and you'll be in business!

PM me for my phone number if you get stuck anywhere along the way, I've done the conversion twice now (don't ask me why, just take it for what it is) and can lead you through if you get stuck!

Here's the diagram, it's pretty starightforward

BrewCityMusic

Oops - forgot to mention, there's no way to actually test an ignitor except for replacing it with a "known good" one (that's straight from EZGO) ...

bajamanjc

You are the man Brewcity, Thanks for the pictures and I will do some shopping this weekend and see if I can't fix this issue.

Thanks