2002 DS No Fire

[Mooncarter]

Hello all. 2002 DS. I not long ago went all through this cart. New fuel pump, lines, throttle cable, micro switches etc. Sat for a while. I started and ran it perhaps a mile or so. Towed it back home. No fire.

Cooled off no fire. Sat for a few days now. No fire.

Before I blame and replace the coil what else should I check. Turns over fine.

Thanks.

[CP241]

Disconnect the ring terminal from the rev limiter. It's a brown wire on the gold bracket underneath the valve cover. See if you've got fire. If so, rev limiter is bad.

If no, then disconnect the black wire at the bullet connector next to the dipstick tube. See if you've got spark. If no, it's a bad coil. If yes, then you've got a microswitch issue or something in the wiring

[Mooncarter]

Thanks CP. Sorry for starting a thread and leaving but something came up.

I'll check those things in the daylight. Been a while since I worked on one of these. Thank you.

[CP241]

Originally Posted by Mooncarter

Thanks CP. Sorry for starting a thread and leaving but something came up.

I'll check those things in the daylight. Been a while since I worked on one of these. Thank you.

No worries my friend. We'll get ya going

[Mooncarter]

Originally Posted by CP241

No worries my friend. We'll get ya going

[Mooncarter]

OK I did all the above, still no fire.

I'm sure it's possible, but I have never had a coil just quit like this. Usually they cool down and will fire again for a while. Perhaps I should check the ground(s) before I replace the coil?

I have replaced dozens of them on small engines but I can see this one will be a real PITA to get to.

[CP241]

If you've got no spark with both the rev limiter and the kill wire disconnected, you could try another plug just in case that may be all it is. But 99% you're looking at replacing the coil.

I know you know better, but just so its said for anyone else reading this, get an OEM coil. Dont bother with an aftermarket unless you have so much fun that you just cant wait to replace it again soon

And yes it sucks. You dont have to remove the motor, but close. You'll need to unbolt it enough to lift it and tilt it sideways a bit to remove the fan shroud. Once you get the shroud off. It's easy to replace the coil. I use a business card as a spacer to set the air gap and never had a problem.

[Mooncarter]

Yeah I've read all the nightmare stories of the cheap coils lasting between 3 and 30 days. I ain't taking that chance. I have the gap gauge to set it right.

I have seen other small engines have surface rust on the flywheel and coil so bad they would not fire. A little sandpaper work and they run like new. I don't think that's the case here.

[CP241]

I doubt it. I've had them be so rusty they look like a brown chia pet and fire just fine

[Fairtax4me]

You don't Have to remove the motor, but for some reason I just hate trying to get those bolts from the engine to transmission housing out with the motor still in the cart. I have multiple floor jacks and 5 pairs of jack stands though, so it's easier for me to just roll the motor and axle out from under the cart in one chunk.

And with the motor out you can change all the spring bushings easy.