Have you ever experienced frustration when your portable generator suddenly stops or won’t start? It is a common issue that many generator owners face, and one possible culprit could be a faulty ignition coil.
But don’t worry, Generator Fixer is here to help through the seven-step process of how to replace the ignition coil for your open-frame models, like Generac, Honda, Briggs & Stratton, etc.. with complete detailed instructions, images, and video to ensure a successful replacement.
How do I know if my ignition coil needs replacing?
If your generator is acting up, such as randomly shutting down, misfiring, or backfiring after running for only 10 or 15 minutes, and you’re using propane or natural gas as the fuel source, it could be due to a weak coil. In my service experience, a weak coil tends to work fine when using gasoline as the fuel.
If some of these symptoms are observed it’s a good idea to consider the ignition coil or spark plug as a possible cause. In such cases change the weak old ignition coil and inspect or replace the old spark plug may help resolve the issue.
How To Change Generator Ignition Coil in (7-Steps) Guide
Tools and Materials (List)
Safety First, before starting any maintenance work on your generator, ensure the generator is turned off and the spark plug wire boot is disconnected to prevent accidental auto starts. Wear safety goggles and working gloves to protect yourself from potential injuries.
Step 1: Access the Ignition Coil
The ignition coil is typically located near the engine under the flywheel cooling cover. You may need to remove the generator recoil starter whole cover not only the pull cord.
Now, take a look at your generator engine flywheel cooling cover. You’ll find either 4 or 5 bolts holding it on. Grab a 10-millimeter socket, remove these bolts, and if needed, use a flathead screwdriver to remove any wire clips. Once you’ve got those off, you can take off the engine shroud and the recoil housing.
Step 2: Unscrew the Wires Boot
After accessing the ignition coil, identify the wires connected to the coil. Simply follow the spark plug wire back to the ignition coil. Carefully unscrew the spark plug wire boot/cap, and then follow the other set of wires leading underneath the panel.
Disconnect the wire connector and make sure to free the wires from any tabs that are holding them in place. These may include the spark plug wire and one wire connecting the ignition switch or electrical connections.
Gently disconnect these wires, making sure to remember their positions for reconnection later.
Step 3: Remove the Old Ignition Coil
With the wires disconnected, you’re ready to remove the old ignition coil. There are two (2) bolts holding it in place. Grab your trusty 10-millimeter socket again and use it to remove those bolts.
Loosen the spark plug wire from the insulator and thread it back through the gap in the carburetor housing. This will allow you to fully remove the old ignition coil.
Step 4: Install the New Ignition Coil
Now, it’s time to install the new ignition coil. Slip it around the flywheel, making sure it’s positioned correctly. Loosely replace the two bolts, and push the ignition coil as far away from the flywheel as you can. Then, tighten up those bolts normally not full tight.
Step 5: Adjust the Gap (Coil to Flywheel)
The most important setting when adjusting the ignition coil to the flywheel on a portable generator is the air gap between the ignition coil and the flywheel magnet.
The air gap is crucial because it determines the strength of the magnetic field generated by the flywheel magnet, which in turn affects the spark produced by the ignition coil. If the gap is too large, the spark may be weak or nonexistent, causing ignition problems.
If the gap is too small, it can lead to the coil and flywheel making contact, potentially damaging both components.
Finally Gap Adjustment
With everything in place, rotate the flywheel until the magnet lines up with the ignition coil. To make sure it’s spaced correctly, grab a business card and cut it in half lengthwise. Use one half as a spacer between the ignition coil and the magnet.
Loosen the two bolts slightly so that the ignition coil fits snugly against the magnet, then give those bolts a good, final tightening with your 10-millimeter socket.
Now, rotate the flywheel to make sure the ignition coil isn’t hitting or rubbing against any part of the flywheel or magnet.
Step 6: Reconnect the Wires
After you adjust the coil gap, attach the wires you disconnected from the old ignition coil to the corresponding terminals on the new coil. Reattach the spark plug cap, and double-check the connections to avoid any loose wires.
Step 7: Replace the Cover or Housing
Start by reattaching any recoil pull starter cover you removed during disassembly and carefully placing them back in their original positions. Use a 10-millimeter socket again and tighten them securely, but be careful not to overtighten, as it may cause damage.
Reattach the spark plug wire boot to the spark plug. This connection is crucial for proper ignition and generator operation.
Final Test the Generator
Before reassembling the generator, it’s a good idea to test it to ensure the new ignition coil is working properly. By testing your generator after replacing the ignition coil, you’re making sure it’s ready for action whenever you need it.
If anything seems off during testing or if you notice any quirks, maybe an oil change or air filter cleaning is required.
Otherwise, reach out to your nearby certified mechanic or fill out the contact form and send your query. A Generator Fixer professional will get in touch with you as soon as possible.
How Much Does It Cost To Replace An Ignition Coil?
The cost to replace a generator ignition coil can vary depending on several factors such as the make and model of the generator, the quality of the replacement part, and whether you’re doing the replacement yourself or hiring a professional.
Typically, ignition coils for generators range in price from $20 to $100 on average, contingent upon the brand and specifications. If you choose to replace the coil yourself, you can save on labor expenses, although this may necessitate investing time and effort into the task.
Alternatively, hiring a professional mechanic or technician for the replacement will likely incur additional labor fees, which can vary depending on the service provider’s hourly rate.
Labor costs for replacing ignition coils are usually billed by the hour. On average, hourly rates can fall between $50 and $100, varying based on the location and the repair facility. The duration of labor needed for ignition coil replacement may range from 0.5 to 1 hour, contingent upon the generator’s structure.
Video Guide
Conclusion
Changing the ignition coil in your traditional generator is an essential maintenance task that can enhance its performance and extend its lifespan.
By following this step-by-step guide, complete with detailed images and video, you can confidently replace the ignition coil and ensure your generator continues to provide reliable power for your needs.
