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Old 01-25-2009, 12:31 AM   #1
Cat797
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Default 96 Club Car DS Intermittent No Go

Hopefully someone can help me here before I dump a bunch of money into this....

I've got a 96 Clubcar DS Gas with an intermittent problem. Sometimes it will run all day long and then all of the sudden it will not start. It can happen as you're driving or if you hop on it and try to go. The motor spins over fine. Then as soon as it stops it will go again, normally about 20 feet at a time, or it can suddenly snap out of it. It usually seems to happen after the cart is warmed up. I've changed plugs. I've checked for spark by taking the plug out and grounding it to the head. It seems to be an intermittent spark problem as sometimes there is spark and sometimes not.

I'm thinking the coil, but then again, I don't know jack about these things.......

Also, does anyone know where I can get a downloadable service manual or do I have to buy a hard copy?

Thanks,
Ed
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Old 01-25-2009, 10:59 AM   #2
GLEEMO
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Default Re: 96 Club Car DS Intermittent No Go

Read this thread
http://www.buggiesgonewild.com/gas-c...-cranking.html

Attached is the diagram for the 1996 Coil and Kill circuit
Check for loose wires and defective switches first.
I strongly recommend purchasing the CC Maintenance Service Manual, if you are planning on keeping this cart (Best $50 I spent) , be careful when purcgasing these on Ebay. The procedures for trouble this problem is in the manual .

Good luck and let me know what you find.
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Old 01-25-2009, 11:08 AM   #3
4vertical
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Default Re: 96 Club Car DS Intermittent No Go

mine with similar problems was the ignitor. also you can use one from a john deere lawn mower with a similar engine. I took mine into the local guy(old timer who had worked on lawn mowers forever) and he had one in stock for like $15.

-Aaron
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Old 01-25-2009, 03:09 PM   #4
Cat797
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Default Re: 96 Club Car DS Intermittent No Go

Thanks for the info.......I guess I'll be ordering up the manual. This is my campground cruiser and we put a lift and wheels and tires on it last year. Other than this problem, I really like the cart.
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Old 01-25-2009, 05:46 PM   #5
GLEEMO
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Default Re: 96 Club Car DS Intermittent No Go

Cat797 to the Forum
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Old 01-28-2009, 08:22 PM   #6
Cat797
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Default Re: 96 Club Car DS Intermittent No Go

Update:

So I ordered 4 of the microswitches (2 x 2-wire and 2 x 3-wire) because I figured at $2.00 I could replace them all for cheap, an igniter and the service manual from Golf Cart Catalog.

Low and behold all of the stuff gets here and the manual is on backorder (would have been helpful to know that before I paid my money) so I have to wait two weeks for that.....

Is the igniter under the side panel of the engine along with the coil?

Thanks for the help.
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Old 01-28-2009, 08:42 PM   #7
4vertical
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Default Re: 96 Club Car DS Intermittent No Go

you should have tried a site sponser!

it is on the front of the engine behind the rpm limiter

-Aaron
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Old 01-28-2009, 08:47 PM   #8
Cat797
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Default Re: 96 Club Car DS Intermittent No Go

Yeah, probably so.......I never even thought about it. I'll have to do that next time.

Thanks for the info
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Old 02-04-2009, 10:43 AM   #9
shadowman
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Default Re: 96 Club Car DS Intermittent No Go

you have to buy one, theres a good chance the coil is bad they were weak that year.............................
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Old 03-14-2009, 10:33 PM   #10
Cat797
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Default Re: 96 Club Car DS Intermittent No Go

Update:

Ok, so I finally got the manual and started to work on the cart...Turns out that in 1996 they switched from a separate ignitor and coil to the 1997 and up style where the ignitor is on the coil. So now I have the wrong part....oh well.

The new problem is that now I am trying to remove the side cover from the engine to access the coil, and I have got all of the screws out of the cover except for one. Many of them are slots on the cover so it slides out without having to completely remove the bolts. However, the one I can't get appears to be an actual hole. It is the one if you are looking at the cooling fan directly at 3:00 and it is blocked by the vertical bracket that looks to be the muffler bracket/mounting bracket for the engine/transaxle. Please tell me that you don't have to pull the engine to get this cover off??? After I get this one bolt out I'm good to go, but looks like I might have to take drastic measures....

Anyone got any ideas?

Thanks,
Ed
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