2011 Drive New TCI No Spark

tohankaaron · 02-19-2015, 11:40 PM

Cart abruptly quit and will not fire. Cranks fine, battery test good.

Followed the Troubleshooting Guide in the Service Manual. "Engine cranks but has NO Spark" First I changed the Spark Plug. NO Spark. TCI tested outside the parameters so I installed a new one (fun, cause you get to pull the motor to reach it). NO Spark. Checked the TCI wire connector plug, air gap on the TCI set at .016 inch, book calls for .012 - .020. NO Spark. Replaced the Spark Plug Cap. NO Spark. Checked the Ground Wires - both good, wiring in good shape. Replaced the Engine Stop Relay. NO Spark. Checked the Throttle Stop Switch, works fine. Repalced the Main Key Switch, NO Spark.

Running out of ideas here. Anyone see this issue before?

Traced the Ignition Circuit and the Ignition Control Circuit on the Electrical Diagram and I have replaced or tested every component.

I could really use you help, Thanks!

cgtech · 02-20-2015, 01:02 AM

Unplug the plug at the base of the motor in front, i think blue & black wires in same plug. Then check spark. The whole ignition system is fully self-contained, the only input it has at all is to short it out (via the plug i suggested unplugging), to prevent it from continuing to make spark. It wants to make spark whenever the flywheel is spinning.

tohankaaron · 02-20-2015, 08:03 AM

Thanks, I will try that out! If I do get spark with that connector un-plugged, then replace/repair issue will be on that short pigtail of wire between the plug and where it ties into the main wiring harness?

BisonGolf · 02-25-2015, 11:31 AM

Had the same problem on my gas cart. Traced it back to the negative cable on the battery. The lug had broke off at the starter. Might be worth checking those cables.

tohankaaron · 02-28-2015, 08:08 AM

Thanks for the help! Engine started fine with that unplugged. TCI unit tested good. I was able to trace the wire harness between the plug and the engine stop relay switch. Found a wire that had rubbed through and was grounding out to the chassis. Made the splice repair. Everything works as it should now.

Thanks!

CAMPERCART2013 · 02-28-2015, 04:04 PM

Nice job cgtech

02-19-2015, 11:40 PM	#1
tohankaaron Not Yet Wild Join Date: Jun 2012 Posts: 13	2011 Drive New TCI No Spark Cart abruptly quit and will not fire. Cranks fine, battery test good. Followed the Troubleshooting Guide in the Service Manual. "Engine cranks but has NO Spark" First I changed the Spark Plug. NO Spark. TCI tested outside the parameters so I installed a new one (fun, cause you get to pull the motor to reach it). NO Spark. Checked the TCI wire connector plug, air gap on the TCI set at .016 inch, book calls for .012 - .020. NO Spark. Replaced the Spark Plug Cap. NO Spark. Checked the Ground Wires - both good, wiring in good shape. Replaced the Engine Stop Relay. NO Spark. Checked the Throttle Stop Switch, works fine. Repalced the Main Key Switch, NO Spark. Running out of ideas here. Anyone see this issue before? Traced the Ignition Circuit and the Ignition Control Circuit on the Electrical Diagram and I have replaced or tested every component. I could really use you help, Thanks!
tohankaaron Not Yet Wild Join Date: Jun 2012 Posts: 13

02-20-2015, 01:02 AM	#2
cgtech Over This Interview Is... Join Date: Jun 2012 Location: AZ Posts: 17,449	Re: 2011 Drive New TCI No Spark Unplug the plug at the base of the motor in front, i think blue & black wires in same plug. Then check spark. The whole ignition system is fully self-contained, the only input it has at all is to short it out (via the plug i suggested unplugging), to prevent it from continuing to make spark. It wants to make spark whenever the flywheel is spinning.

02-20-2015, 08:03 AM	#3
tohankaaron Not Yet Wild Join Date: Jun 2012 Posts: 13	Re: 2011 Drive New TCI No Spark Thanks, I will try that out! If I do get spark with that connector un-plugged, then replace/repair issue will be on that short pigtail of wire between the plug and where it ties into the main wiring harness?
tohankaaron Not Yet Wild Join Date: Jun 2012 Posts: 13

02-25-2015, 11:31 AM	#4
BisonGolf Getting Wild Join Date: Feb 2014 Posts: 78	Re: 2011 Drive New TCI No Spark Had the same problem on my gas cart. Traced it back to the negative cable on the battery. The lug had broke off at the starter. Might be worth checking those cables.
BisonGolf Getting Wild Join Date: Feb 2014 Posts: 78

02-28-2015, 08:08 AM	#5
tohankaaron Not Yet Wild Join Date: Jun 2012 Posts: 13	Re: 2011 Drive New TCI No Spark Thanks for the help! Engine started fine with that unplugged. TCI unit tested good. I was able to trace the wire harness between the plug and the engine stop relay switch. Found a wire that had rubbed through and was grounding out to the chassis. Made the splice repair. Everything works as it should now. Thanks!
tohankaaron Not Yet Wild Join Date: Jun 2012 Posts: 13

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02-28-2015, 04:04 PM	#6
CAMPERCART2013 Gone Wild Join Date: Nov 2013 Posts: 1,088	Re: 2011 Drive New TCI No Spark Nice job cgtech

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