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Old 07-19-2020, 05:20 PM   #1
1arunem
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Default 2004 DS no spark, diagnosis so far..

Trying to help a friend with his 2004 Club Car DS. Went out to it one day and it wouldn't start. Spins over fine, but no spark..

Disconnected rev limiter ground strap, still no spark.

Disconnected bullet connector on white/black stripe that goes to limiter. I now have spark.

What does this tell me? Coil ok? Other things to look at?

I am very familiar with some Yamaha models but only fiddled with a couple DS carts.

Thanks!
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Old 07-19-2020, 05:36 PM   #2
CP241
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Default Re: 2004 DS no spark, diagnosis so far..

Disregard what I had typed previously. I read incorrectly.

If you disconnect the black/white wire and have spark then you have an issue with either the key switch or a microswitch. Should be the microswitch in the black electrical box. There are 2 of them. This should be the one on the bottom. They're cheap and easy to test and replace. Usually it's quite obvious if the button the "flag" hits is slow.or.sticky
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Old 07-19-2020, 08:38 PM   #3
1arunem
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Default Re: 2004 DS no spark, diagnosis so far..

Would you happen to know which wires go where on the micro switches in the throttle cable box? diagram? I suspect someone has been in here before me.

Upper micro switch has a white/blk wire and an orange wire (orange goes to solenoid).
Lower micro switch has a green and a black.

Micro switch action seems good but.... Best way to test?
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Old 07-19-2020, 10:01 PM   #4
CP241
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Default Re: 2004 DS no spark, diagnosis so far..

Quote:
Originally Posted by 1arunem View Post
Would you happen to know which wires go where on the micro switches in the throttle cable box? diagram? I suspect someone has been in here before me.

Upper micro switch has a white/blk wire and an orange wire (orange goes to solenoid).
Lower micro switch has a green and a black.

Micro switch action seems good but.... Best way to test?
This is the best I can do without seeing a cart in front of me. Everything in the diagram is oriented just like it is in the cart

Upper should be green and orange.

Lower should be black and white/black

I'm thinking they're mixed up
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Old 07-20-2020, 07:22 AM   #5
1arunem
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Default Re: 2004 DS no spark, diagnosis so far..

Here are pictures of how they are. As you can see the one switch (was in the upper position) has white/blk and orange. Lower switch had green and black.

The cart will run this way with the white/blk disconnected at the bullet connector. It will not fire with the white/blk at the bullet connector attached.

I tried hooking them up green and orange and white/blk and blk but get no response when hitting the pedal.

I will try to trace back all the wires this evening to see if the rest are as factory.

Thanks for your input! It is greatly appreciated.
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Old 07-21-2020, 06:56 AM   #6
1arunem
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Default Re: 2004 DS no spark, diagnosis so far..

Just an update. Put the wires back the way they go with the micro switches in the correct positions (they were switched up) and she runs.

Apparently who ever had been fiddling with this thing previously had them mixed up.

Thanks for the diagram CP241!
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Old 07-21-2020, 11:20 AM   #7
CP241
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Default Re: 2004 DS no spark, diagnosis so far..

People always fiddle with crap and seldom put it back the way they got it. Usually when I buy a new cart I spend the first couple days finding all of the previous owners "fixes" and putting back the way it should be from the factory. And THEN start diagnosing the real problems.

Half the time there are no "real" problems. Just previous ninja repair jobs that didnt work out
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