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Old 04-13-2012, 08:13 AM   #1
willyjoe
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Default Spark Issue Stumped!! 96 TXT

Good morning all I have a 96 TXT with the twin cylinder robin engine and I just can't get it running, ign coil is good (tested it on a friends cart) replaced the ignitor with the HEI conversion replaced the pulsar coil yesterday however I have a suspicion that this is still the issue. When I check the readings on the pulsar they are exactly the same as the one I took off resistance is 20 OHMs with 250mV AC when cranking. Could it just be that I set the air gap incorrectly? The pulsar I took off was completly missing the metal pickup that sticks out. I set the air gap on the new one to .025, I set it with the pulsar lined up with the "gap" on the flywheel. Any ideas are greatly appreciated, I'm at about wits end with this thing!

Thanks
Joe
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Old 04-14-2012, 07:30 AM   #2
willyjoe
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Default Re: Spark Issue Stumped!! 96 TXT

Anyone? What else should I look for? Any direction is welcome, I'm stuck like a mime in a clear box over here... Did I get defective new part?
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Old 04-14-2012, 09:27 AM   #3
Dave Box
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Default Re: Spark Issue Stumped!! 96 TXT

Joe, I am not an expert on the 4 stroke EZGO engine so you accept or reject my advice and you won't hurt my feelings. That said I do have a mechanical aptitude and I have worked on two for friends. I can tell you from painful experience that the readings you are seeing on the pulsar are correct. I am used to the 2 stroke pulsar which ohms out at ~100 ohms so when I saw 20 ohms on my buddy's I bought a new one, only to find the new one was also 20 ohms.

So you swapped out the coil (and the spark plug leads?) and it worked, we can rule that out. You have replaced the ignitor with a HEI and still no joy. I am sure that the pulsar is good so that is the ignition taken care of. This leaves the wiring.

As a quick check connect your voltmeter to the negative of the battery and the positive of the coil, crank the engine, do you see ~12 volts? If you do then we look deeper. All carts suffer from ground issues so I would first look at that plate that holds the ignitor and the regulator. You should see several black wires, remove these and clean the studs they attach to and the cable lugs themselves. Also find the main ground point on the chassis and do the same. That might be all it takes. If not then look for a broken wire or pin connector. Take each connector apart and give it a shot of WD40. Also tug gently on each wire to see if it falls apart.

You said that you saw 250 mVolts out of the pulsar when cranking so I almost hesitate to bring this up but.............
I was working on a cart with the same symptoms and two days later I discovered that the clutch was loose on the shaft so when you cranked it everything span but the engine. Putting my thumb over a spark plug hole when cranking would have set me on the right path.

Such is life
Dave
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Old 04-16-2012, 08:06 PM   #4
willyjoe
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Default Re: Spark Issue Stumped!! 96 TXT

Thanks Dave I will check all of that out this week. I do have spark, but its weak. Also is there any way for the timing on these carts to get out of tolerance?

Thanks
Joe
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Old 04-16-2012, 08:38 PM   #5
Dave Box
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Default Re: Spark Issue Stumped!! 96 TXT

Joe,
The pulsar is in a fixed position on your cart so the ignition timing will not slip. A weak spark could be indicative of a bad ground somewhere so good luck. Also many people have reported that swapping the polarity of the wires from the pulsar have solved a weak spark issue so that might be worth trying.
Dave
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Old 04-16-2012, 08:51 PM   #6
willyjoe
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Thanks, hopefully I will get a chance to work on it tomorrow and I will report my findings. I really do appreciate all the help!

Thanks
Joe
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Old 05-17-2012, 06:06 AM   #7
kantuckian
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Default Re: Spark Issue Stumped!! 96 TXT

Good info
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Old 06-27-2012, 04:33 AM   #8
pcweber
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Default Re: Spark Issue Stumped!! 96 TXT

Willyjoe, did you come to a solution? I too have weak spark on a 295 engine and would love to hear the story ending.
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Old 10-24-2015, 09:03 AM   #9
Texas001
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Default Re: Spark Issue Stumped!! 96 TXT

Quote:
Originally Posted by pcweber View Post
Willyjoe, did you come to a solution? I too have weak spark on a 295 engine and would love to hear the story ending.
They never seem to post the final results.
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Old 10-27-2015, 09:39 PM   #10
toxicwaste29
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Default Re: Spark Issue Stumped!! 96 TXT

Quote:
Originally Posted by pcweber View Post
Willyjoe, did you come to a solution? I too have weak spark on a 295 engine and would love to hear the story ending.
If a flywheel is to rusted that could also have been an issue. I would shoot him a pm so maybe it pops up in his email and he knows to log on and update the results.
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