Driving me nuts.

[KJRH]

I have a 1995 G9, having an issue with it and it is driving me crazy.. My first question is how important is the dip stick seal.. Mine is lose... Will this effect the vacuum operated fuel pump? After driving for a while(10minutes) sometimes when you try to take off it will just sputter... If you very very slowly press the gas pedal eventually it will take off... I have check for spark when this condition shows up and it has nice blue spark... Quick run down on what I have done to buggy.
Fresh .010 over bore 4 months ago.
New Primary Clutch
New belt
Plowmans Exhaust and jet kit
New intake adapter
Cleaned carb.
Checked valve lash..
ran a ground from battery to engine..
Fuel lines and filter, air cleaner, inspected pulse lines (look great) Help please.. My wife wont drive it anymore and she said sell it... Thanks for all of the help...(could a malfunctioning governor cause an issue like this?)

[Dave in VA]

Yep, the dipstick seal needs to be tight. Heat shrink or duct tape...

[KJRH]

Awesome, thank you i will seal it when I get home tonight...

[KJRH]

Well, I sealed up the dipstick with some cool Loc-tite red strechy rubber tape stuff, worked great, still had the issue, and now last night she finally broke and wont come back from the dead.... No spark at all.. I know there is no good answer for this fix.. I just need to start testing and replacing crap.... If anyone has any idea's it would be great..Tried new plug, It does have the original coil and ignitor.. Hell even has the original spark plug boot... I have some work to it seems.

[KJRH]

I dont no where to begin, I had intermittent spark with old ignitor, did all of the test by the book and everything pointed to the ignitor so I bought one, same thing.. Intermittent spark... What should I do? Trigger coil tested fine, coil tested fine (primary and secondary) please I need help quick.. going camping this wkend and I will be in the dog house... Thanks

[KJRH]

I checked pulse coil and ignition coil, pulse coil was 565 ohms, Ignition coil primary was 3 ohms, is low.. Secondary was 13.75 ohms.. Spark plug cap/boot was 5.2 ohms...

[Mike Mac]

I would start looking for a bad-loose-dirty ground connection.

There is a small 16 gauge black wire coming off the starter ground lug on the end of the starter, then going into the main wire harness just in front of the starter. That eyelet on the starter end has a tendency to go bad!! Cut that eyelet off and strip the wire back a half inch and attach a new eyelet on!!

If you have any accessories (lights, radio etc) all grounds go back to the battery negative post!!

[KJRH]

Thanks Mac Attack, I will try that soon as I get home... It has to be a bad wire somewhere, to have intermittent spark like that doesnt jive with bad ignition parts.. (right) Correct me if I am wrong, they are either good or bad? At least at room temperature?? I have had coils and CDI units act up once they get hot... Never anything like this.... After I replace eyelet and I still have issue, is there anyway to "Hot wire this thing straight from the battery to ignitor. then I can work my way back thru the system.....

[Mike Mac]

That I can't help with. Big stick is the one that might know the answer to that question!!

[CAMPERCART2013]

Originally Posted by KJRH

Thanks Mac Attack, I will try that soon as I get home... It has to be a bad wire somewhere, to have intermittent spark like that doesnt jive with bad ignition parts.. (right) Correct me if I am wrong, they are either good or bad? At least at room temperature?? I have had coils and CDI units act up once they get hot... Never anything like this.... After I replace eyelet and I still have issue, is there anyway to "Hot wire this thing straight from the battery to ignitor. then I can work my way back thru the system.....

In my case temperature had no effect on the intermittent spark issue! No rhyme or reason! Ride time or temperature had no effect on it! Ran great when it wanted and fell on its face when it didn't! Cdi ignitor whatever you want to call it Was the issue!