How to Change the Ignition Coil in Your Portable Generator Step-By-Step Guide

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Have you ever experienced the frustration of your open-frame portable generator suddenly stalling or refusing to start? It is a common issue that many generator owners face and one possible culprit could be a faulty ignition coil.

But fear not, This step-by-step instruction will walk you through the process of replacing the ignition coil for your portable generator, Complete with detailed instructions and images to ensure a successful ignition coil replacement.

If your generator is acting up, like randomly shutting down or misfiring after running for only a short time, like 10 or 15 minutes, it is a good idea to consider the ignition coil as a possible cause. In such cases, replacing the ignition coil might help resolve the issue.

Ignition Coil Replacement for Open-Frame Generator

How to Replace Ignition Coil in Your Traditional Generator?

Step 1: Tools Need

Before you begin, make sure you have the necessary tools & parts on hand:

  • Screwdriver
  • T Handle socket wrench 10-millimeter, 8-millimeter both
  • New ignition coil
  • needle nose pliers
  • Safety goggles

Step 2: Access the Ignition Coil

First things about safety. You don’t want any unexpected sparks, right? So, start by disconnecting the spark plug cap.

ignition coil replacement

That’s done 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.

ignition coil replacement

Step 3: Disconnect the Wires

After accessing the ignition coil then Identify the wires connected to the ignition coil. simply follow the spark plug wire back to the ignition coil. Carefully unscrew the spark plug cap, and then follow the other set of wires leading to underneath the panel.

Disconnect the wires 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 4: 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 5: 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.

Step 6: 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 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 7: Reconnect the Wires

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 8: Replace the Cover or Housing

Start by reattaching any recoil pull starter cover you removed during disassembly and carefully place them back in their original position.

Use a 10-millimeter socket again and tighten them securely, but be careful not to overtighten, as it may cause damage.

Step 9: Reconnect the Spark Plug Wire

Reattach the spark plug wire to the spark plug. This connection is crucial for proper ignition and generator operation.

Step 10: Test the Generator

By testing your generator after replacing the ignition coil, you are making sure it’s ready for action whenever you need it.

If anything seems off during testing or if you notice any quirks, consult your manual or consider reaching out to your nearby certified mechanic.

Proper testing and maintenance will keep your generator running smoothly for a long time to come. issues.

Conclusion: Ignition Coil Replacement Process

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, completely with detailed images, you can confidently replace the ignition coil and ensure your generator continues to provide reliable power for your needs.

Remember, if you’re uncertain or uncomfortable with any step, it’s always a good idea to consult a professional technician nearby area.

FAQs: About Changing Ignition Coils in Portable Generators

Can I change the ignition coil without professional help?

Absolutely! Changing the ignition coil is a task that can be done by most DIY enthusiasts. Just follow our guide for a successful replacement.

What tools do I need for this task?

You’ll need a screwdriver, wrench, safety gloves, safety goggles, and the new ignition coil.

Why is changing the ignition coil important?

The ignition coil plays a crucial role in generating the spark that ignites the fuel-air mixture in your generator’s engine. A faulty coil can lead to starting problems and poor performance.

How do I know if my ignition coil needs replacement?

If your generator is having trouble starting, misfiring, or running erratically, a faulty ignition coil might be the culprit. A professional diagnosis is recommended.

Are there any risks involved in changing the ignition coil?

While it’s a relatively simple task, safety is key. Always disconnect the spark plug wire and work in a well-ventilated area. If you’re uncertain, it’s best to seek professional assistance.

About Saad Ahmed
Hi am Saad Ahmed and as you can see that i have been a generator mechanic for the past 12 years of experience in this industry. But now i am Full time digital marketer and affiliate blogger.