Go Kart Ignition System Repair

Last time we went through the steps of diagnosing the faulty ignition system. We first tested for:

- Gas
- The switch was on
- Plenty of Compression
- Spark.

We discovered that the culprit was no spark. We also determined that the "No Spark" was coming from the ignition system, not clogged spark plugs or things like that. For whatever reason, the ignition system was not putting out.

We also determined that the shutdown system (the on-off circuitry) was not the problem.

So our next step was to look at the key that lines up the flywheel to the coil. Actually, with the solid state ignition, you should still get spark, but just at a different starting point in the cycle. Either advanced or retarded.

So the real culprit is the non-firing coil.

So what do you do? There are two options: find a similar engine that is sitting around and take its Magneto (coil), or buy a new Magneto.

Most people don't have engines sitting around, so buying is the next best thing.

Be prepared to pay $50 for a Magneto. Also, it is handy to bring in the blower cover to the shop to let the tech read the correct Model and Serial Number.

In any case, be sure to get the correct Model Number and Serial Number for your engine. Also they will treat you better if you have these numbers before asking for the part. Call the part the correct name and they respect that as well.

To place the new magneto in place, fold a sheet of paper in half so it is two pages thick or even three pages. Then place the paper between the flywheel and the magneto. This will create the necessary gap for good ignition. If the gap is too large, then the spark may be weak. Too close and you will damage the coil and the flywheel.

You can rotate the engine so that the magnet attracts the magneto. Then tighten. Or your can just press down lightly on the magneto (so the paper , the magneto and the flywheel are compressing together) and tighten as well. Either method works fine.

I prefer, however, pressing the magneto down, because the magnet can attract more than I like and actually get the clearance between the flywheel and the magnet a little too close.

The first thing you want to make sure is that the Magneto is working. I like to just have the spark plug sit on the head and then spin the engine over. If there is spark, then the system is working properly.

Put it all back together!

Test run it!

Bottom line is that ignition is the first step in in testing why an engine is not running. Always check the electrical side of the engine first, then start digging deeping in the diagnosis of the engine problem.

Our main problem was an engine not running, there could have been other issues such as no fuel, bad valves or even a blown rod.