Ignition coil keeps going bad

Jls2292 · 10-02-2018, 07:36 PM

I have a 1996 club car ds gas and my ignition coil keeps going bad. I have replaced it 2 times already. Every time I put a new coil on it will last for about a month or two of hard riding before it goes bad again. I replaced all micro switches, solenoid, ground wire that leads to the ignition coil, and have eliminated the rev limiter. I have tested the ground wire leading to the ignition coil and while the engine runs it it showing 0.09-0.15 volts. I have also tested the frame and it is showingthe same voltage. Is it common to have low voltage running through the frame and ground wire? And if not could that be what is making my ignition coil go bad over time? Help is greatly appreciated! 😁

tony357 · 10-02-2018, 09:26 PM

have you replaced the ignitor?

Jls2292 · 10-03-2018, 02:04 AM

Tony356 the golf cart is a 1996 but from my understanding they started putting 1997 parts in the carts half way through the year and according to a tech guy the guy I bought it from called when he was having this problem said my cart is the 1997 version which has the ignitor with the ignition coil. Those coils are the ones I have been buying. But just to make sure I will check behind the rev limiter to see if there is one there. Unless I am wrong and they all have one behind the rev limitor?

meimk · 10-03-2018, 06:10 AM

Also, do not bother putting in anything but the o.e. Kawasaki brand coil . I’ve seen too many aftermarket coils for these Club Cars do exactly what you described - fail in a matter of days or weeks. Unfortunately the coils from even the recognized golf cart parts houses are as bad as the cheapest thing you can find on ebay. If it's a part #5133 or ENG-106, it's going to fail. The Kawasaki part # is 21171-2207. If you shop carefully it's not much more than the garbage ones, honesty less than some vendors sell the bad ones.

tony357 · 10-03-2018, 06:32 AM

two things to check.
1. see if spark plug changed with ignition style resistor could be different.
2. check to see if engine is over heating or coil overheating due to poor ventilation.

EDIT: I am an marine tech just throwing some suggestions out there. I do know a buggy tech though ill ask when I see him.

Fairtax4me · 10-03-2018, 08:45 AM

Are you using OE Kawasaki coils? Cheapo coils fail all the time.
What gap are you running on your spark plugs? Too wide of a gap will make the coil burn out.

TahoeDawgZ71 · 10-03-2018, 05:21 PM

OEM# 101909201. It's the style with the ignitor built into the coil. As mentioned in the above post, aftermarket coils are junk and they don't last. Put one of these on it and un-plug your external ignitor and it'll work fine.

Jls2292 · 10-03-2018, 06:20 PM

I will double check if I am using an oem part I am pretty sure the guy I bought it from said they were oem. Fairtax4me I'm not sure what spark plug gap I have in there but I will replace the spark plug anyway. What gap should be in there?

10-02-2018, 07:36 PM	#1
Jls2292 Not Yet Wild Join Date: Oct 2018 Posts: 3	Ignition coil keeps going bad I have a 1996 club car ds gas and my ignition coil keeps going bad. I have replaced it 2 times already. Every time I put a new coil on it will last for about a month or two of hard riding before it goes bad again. I replaced all micro switches, solenoid, ground wire that leads to the ignition coil, and have eliminated the rev limiter. I have tested the ground wire leading to the ignition coil and while the engine runs it it showing 0.09-0.15 volts. I have also tested the frame and it is showingthe same voltage. Is it common to have low voltage running through the frame and ground wire? And if not could that be what is making my ignition coil go bad over time? Help is greatly appreciated! 😁
Jls2292 Not Yet Wild Join Date: Oct 2018 Posts: 3

10-02-2018, 09:26 PM	#2
tony357 Not Yet Wild Join Date: Oct 2018 Posts: 67	Re: Ignition coil keeps going bad have you replaced the ignitor?
tony357 Not Yet Wild Join Date: Oct 2018 Posts: 67

10-03-2018, 02:04 AM	#3
Jls2292 Not Yet Wild Join Date: Oct 2018 Posts: 3	Re: Ignition coil keeps going bad Tony356 the golf cart is a 1996 but from my understanding they started putting 1997 parts in the carts half way through the year and according to a tech guy the guy I bought it from called when he was having this problem said my cart is the 1997 version which has the ignitor with the ignition coil. Those coils are the ones I have been buying. But just to make sure I will check behind the rev limiter to see if there is one there. Unless I am wrong and they all have one behind the rev limitor?
Jls2292 Not Yet Wild Join Date: Oct 2018 Posts: 3

10-03-2018, 06:10 AM	#4
meimk Gone Wild Join Date: Jun 2011 Location: Northern Indiana Posts: 2,827	Re: Ignition coil keeps going bad Also, do not bother putting in anything but the o.e. Kawasaki brand coil . I’ve seen too many aftermarket coils for these Club Cars do exactly what you described - fail in a matter of days or weeks. Unfortunately the coils from even the recognized golf cart parts houses are as bad as the cheapest thing you can find on ebay. If it's a part #5133 or ENG-106, it's going to fail. The Kawasaki part # is 21171-2207. If you shop carefully it's not much more than the garbage ones, honesty less than some vendors sell the bad ones. Last edited by meimk; 10-03-2018 at 06:37 AM.. Reason: Additional info

10-03-2018, 06:32 AM	#5
tony357 Not Yet Wild Join Date: Oct 2018 Posts: 67	Re: Ignition coil keeps going bad two things to check. 1. see if spark plug changed with ignition style resistor could be different. 2. check to see if engine is over heating or coil overheating due to poor ventilation. EDIT: I am an marine tech just throwing some suggestions out there. I do know a buggy tech though ill ask when I see him.
tony357 Not Yet Wild Join Date: Oct 2018 Posts: 67

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10-03-2018, 08:45 AM	#6
Fairtax4me Bonafide Nincompoop Join Date: Dec 2015 Location: Charlottesburg Va Posts: 8,987	Re: Ignition coil keeps going bad Are you using OE Kawasaki coils? Cheapo coils fail all the time. What gap are you running on your spark plugs? Too wide of a gap will make the coil burn out.

10-03-2018, 05:21 PM	#7
TahoeDawgZ71 revolutiongolfcars.com Join Date: Mar 2010 Location: Golf Car Capital of The World... Augusta, Georgia Posts: 10,224	Re: Ignition coil keeps going bad OEM# 101909201. It's the style with the ignitor built into the coil. As mentioned in the above post, aftermarket coils are junk and they don't last. Put one of these on it and un-plug your external ignitor and it'll work fine.

10-03-2018, 06:20 PM	#8
Jls2292 Not Yet Wild Join Date: Oct 2018 Posts: 3	Re: Ignition coil keeps going bad I will double check if I am using an oem part I am pretty sure the guy I bought it from said they were oem. Fairtax4me I'm not sure what spark plug gap I have in there but I will replace the spark plug anyway. What gap should be in there?
Jls2292 Not Yet Wild Join Date: Oct 2018 Posts: 3

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