Coils failing on 1993 club car

[gl4276]

I have a 1993 club car and have problems with the coils. It ran perfect for 2 years then the coil failed. I took it the authorized dealer and they replaced the coil and it ran fine for about 1 to 3 months. They replaced the coil 3 times and since then I have had to replace the coil 6 times about every 3 months.The gap is correct from the coil to the flywheel. The dust cover is on correctly so the fan works properly. The spark plug is not fouled and is working good but the spark appears to be weak on all the coils that I have installed. Could anyone comment what could be causing the coils to fail and recommend how to correct the problem..

[golfcartg]

It sounds like you’ve been through quite a few coils which makes me wonder if the coil is really the problem. The ignition system on your Club Car includes not just the coil but also the ignitor, which could be the culprit here. The ignitor controls the strength of the spark and when it starts to fail it can send inconsistent signals to the coil causing what seems like weak or intermittent spark. Inside the ignitor, components like the transistors and capacitors are responsible for controlling the ignition and managing the electrical jolt sent to the coil. If one of these components is degrading, it could easily cause your coil to underperform. The ignitor is located on the engine block behind the rpm limiter (see attached photo) and is the size of a postage stamp.

Make sure you're using an OEM spark plug, not a cheaper aftermarket version you might find on Amazon. Many of those are clones, even if they carry a brand name, and they can lead to weak or inconsistent spark. I’ve seen cases where a knockoff plug causes similar issues even if it looks brand new.

Lastly, when it comes to ignition parts always stick with OEM. Aftermarket parts especially for ignition systems can be hit or miss. They use lower quality materials in critical areas like the windings and internal insulation which leads to performance issues. You’re better off spending a little extra upfront to avoid constant replacements so everything runs as it should.

[Scottydont]

Check to see if it has an igniter. It is is a little square by the rev limiter. It’s like 1” by1” and has single prong connector in series with rev limiter

[Scottydont]

…also in Kawasaki engines there are 2 different igniters. I don’t remember which one but one will trigger at lower rpm than the other. Find a good tractor tech and they could tell you which fires at lower rpm