89 EZGO - Electrical System Overhaul

[cart around]

There are some decisions to be made here.

Is there enough blue wire left at the coil to splice on some new wire?

If not, you are looking at a new coil. A factory coil is $127. Not a big deal, but we don't know if the ignitor was ruined along with the coil. We need to find out.

Now you need to decide if you want to go all original, or if it's time to do the HEI mod.

The coil I used for my HEI mod is up to $20 now. My module was $15, but I think it's going for around $50-$60 now. Are you up for some more wiring?

That's why I say to try splicing the blue wire first, then make some decisions.

https://diygolfcart.com/ezgo-ignitio...e-gas-1981-94/

https://diygolfcart.com/ignitor-for-...1990-marathon/

[Pope]

I don't think there's enough blue wire to splice to. It is toasted almost all the way into the coil housing.

I'm thinking it is time to do the HEI. If you'll indulge more ignorance being painfully transformed to experience, I would appreciate it.

Do people mostly do this because it is more reliable or just cheaper?

Just ordered from Advanced Auto with $10 off coupon and 20% off, $49

[cart around]

It's cheaper, and produces better spark.

[Pope]

I did it!...kinda....

Got the parts in and put the female connectors on the wires, drilled holes to mount the ignition coil and igniter. Fired it up and rode to the pool and back. As we pulled into the house, it died. No spark. Taking a break now...about to go see if I have voltage going to the coil I think...maybe it'll be an easy fix

[cart around]

It may have burned up the HEI module. You need dielectric grease, and bare metal for a good heat sink.

You should also have 5 wires to the module.

Red, and blue wires to the pulsar.

C goes to the negative terminal on the coil

B goes to the positive terminal on the solenoid, and the positive side of the coil.

The 5th wire that most people miss goes to the module mounting hole, and to ground.

If your module has little nubs on the back, They need to be sanded off, or drill little indents for them to fit into when mounted. The module needs to sit down tight with grease for heat dissipation.

[Pope]

Originally Posted by cart around

It may have burned up the HEI module. You need dielectric grease, and bare metal for a good heat sink.

You should also have 5 wires to the module.

Red, and blue wires to the pulsar.

C goes to the negative terminal on the coil

B goes to the positive terminal on the solenoid, and the positive side of the coil.

The 5th wire that most people miss goes to the module mounting hole, and to ground.

If your module has little nubs on the back, They need to be sanded off, or drill little indents for them to fit into when mounted. The module needs to sit down tight with grease for heat dissipation.

I got the nubs off. I didnt add any grease but did clean the metal fairly well. Any way to test it or just buy another one?

I did have the 5 wires. Once I found the letters on the module it was a piece of cake.

[Pope]

Found a new one at advanced auto for $17. Got it replaced....runs like a champ.

I do get an occasional "putt" like a misfire when it's going downhill. Is that a governor??

[cart around]

Sometimes you have to switch the red, and blue pulsar wires to see which way runs best.

There is no governor in the module.


You should be feeling pretty good about getting that running.

[Pope]

Double post

[Pope]

Originally Posted by cart around

Sometimes you have to switch the red, and blue pulsar wires to see which way runs best.

There is no governor in the module.


You should be feeling pretty good about getting that running.

Thank you....I give you the credit (and the dude that wrote up the instructions for HEI module). Definently enjoyed cruising around today.

I think I'm going to switch them tomorrow....I would have to wait a bit for it to finally catch and take off later today. Felt like dirty carb....so I cleaned it but similar result.

Also...what have other folks used to replace the tube from air intake to filter?