electric issue/questions G16A

[dperillo]

Hello, New to forum. So I've been working on a 1996 G16A cart. Had a hard start issue and low compression. I figured the start issue was from the low compression so I rebuilt the engine. Carb shaft was bad so replaced carb. Did piston, rings, valves, springs, guides, push rods. all that.

Well I now have good compression but the start issue is still there. It appears to flood out if you dont just barely touch the gas peddle. It always has spark, but I don't think its good spark. My thoughts are the spark is weak and or out of time which is making it flood.

Im not real familiar with these cart 12 volt setups and looking for some advice on what to check or on how this system works.

Some things I did already:
Tested coil by the book. Ohm's test shows ok. Maybe slightly high on the .5 to 1.5 test. I was reading about 1.9

I do see that the coil air gap is really high. Supposed to be .012" - .020". It at least double that, but cant adjust it any closer. Maybe I can grind out the bolt slots.

Followed the no spark procedure in the book. Everything checks out and I do have spark, just think its week or out of time. When everything checks out by the book, book says replace stop switch.

The stop switch... I test and seems ok. QUESTION.. there is 12v going into the switch but only .5v coming out of the blue wire. Is this ok? seems like the coil should be getting more then .5v If I jumper this switch, so the blue wire is seeing 12v, then there is no spark at all. ??

Ground wires. Not sure whats up here. This cart will still spark without the wire to the coil. ??? It has to be picking up some type of voltage thru the engine, right??? very confused on that one.

So that was long and hard to lay out everything but any help is much appreciated. This thing is kicking my butt. lol. I don't want to just throw money at it.

Thanks guys..

[Dave in VA]

Did you test the stop switch--under the floor, or the stop relay?

[Dave in VA]

OEM or aftermarket coil/TCI?

I use a matchbook cover for the gap.

[cgtech]

The ignition system makes spark from the magnet in the flywheel. The blue wires job is to shut down the coil by grounding it out,. It will make spark with the blue wire not connected. Since it wont adjust correctly, I suspect it's a chinese copy of the original. The original will adjust until it touches the flywheel.

[dperillo]

Originally Posted by Dave in VA

Did you test the stop switch--under the floor, or the stop relay?

I did the engine stop relay by the battery. Next to the solenoid. That's what they call it in the book.

The relay will trigger, but when engaged the 12v going in
(red & white wire) turns to .5v going out (blue wire).

The blue wire is the one going to the coil.

Thanks..

[dperillo]

Originally Posted by Dave in VA

OEM or aftermarket coil/TCI?

I use a matchbook cover for the gap.

I'm not sure, I would think aftermarket based on hearing the cheap coils don't adjust correctly. I have heard of the business card trick as well. Book says .012 to .020. This one is way more then that.

Thanks

[dperillo]

Originally Posted by cgtech

The ignition system makes spark from the magnet in the flywheel. The blue wires job is to shut down the coil by grounding it out,. It will make spark with the blue wire not connected. Since it wont adjust correctly, I suspect it's a chinese copy of the original. The original will adjust until it touches the flywheel.

Do you know of a way to check the engine stop relay? Its about a $70 item. Dont want to just replace if I cant really determine if its bad. I'm thinking to replace the coil anyway. It has to be a chinese one like you said. Although it did ohm test ok.

Any thought on grinding out the bolt holes to let the coil be adjusted??

Would being to far away from the flywheel cause a timing issue?

Thanks

[cgtech]

Heres the diagram with all the info on the stop relay plug.

[dperillo]

Originally Posted by cgtech

Heres the diagram with all the info on the stop relay plug.

So if I understand this correct. The relay gets 12v thru red/white wire when gas peddle is pushed. It then opens the relay so coil is not grounded and spark goes to plug. When peddle is let off, the red/white wire loses 12v and the relay closes which grounds the blue wire and coil to stops spark from going to plug.

So with that, I would say it's probably not my issue. Only thing I could see happening there is the cart wouldn't shut off, or wouldn't have any spark at all.

I'm leaning toward the coil being too far away from pickup and the timing not right. Possible junk coil as well. This start issue has been there since the cart was bought. So its possible they put this china coil on and then sold cart.

Gonna get a new coil.....

Thanks guys. I'll let ya know how I make out.

[cgtech]

I think you understand it correctly.

And, that relay is definitely not a common failure item.