Club Car 2007 XRT 800, Maintenance Service Manual, Page: 268 / 516

ENGINE General Information
Page 15-2 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual
15
Spark Plug Cleaning, Inspection and Repair
Examine the plug (Figure 15-1, Page 15-2) . The deposits on the plug base and electrode are an indication of
the correct heat range and efficiency as well as a guide to the general condition of the engine, fuel and air mix-
ture and ignition system. If all of the above conditions are proper, the spark plug should be a light brown color.
There should be no bridging between the electrode and base. The electrode should not be eroded. Black
color, excessive carbon, and/or a wet plug indicates that the fuel is too rich. White, burned or melted elec-
trodes indicate the fuel is too lean or pre-igniting. Oily deposits on the plug electrode are an indication of worn
rings, valve guides, cylinder wall, etc. Also examine the spark plug wire. Remove rubber boot and inspect
internal spring for damage. Inspect spark plug wire for damage and be sure spring coil is securely attached to
spark plug.
See following WARNING .
ý
WARNING
• Remove spark plug wire to avoid accidental start up of the engine when servicing vehicle. To
avoid ignition of fuel and serious personal injury or death, never try to start the engine with
plug removed from engine.
Testing the Spark Plug
Check the sparking ability of a cleaned and properly gapped plug on a sparking comparator if possible. Spark
should be blue and strong and able to jump a 5/16-inch (8 mm) gap.
Setting the Spark Gap
1. Pass a contact point file between the electrodes to produce flat, parallel surfaces to facilitate accurate
gauging.
2. Use a wire type gauge. Bend the outside or ground electrode so only a slight drag on the gauge is felt
when passing it between the electrode. Never make an adjustment by bending the center electrode. Set
gap (A) to 0.027-0.031 inches (0.69-0.79 mm)
(Figure 15-1, Page 15-2) .
Spark Plug Installation
NOTE: Before installing the plug, check the condition of the threads in the cylinder head. Soften deposits
in cylinder head threads with penetrating oil and clean the threads with a tap if necessary.
Use a high temperature, anti-seize lubricant on the threads of the spark plug to reduce friction
when installing a new plug, and reduce “gauling” and thread seizing for future replacements.
1. Install the spark plug by threading it in until finger tight, then tighten the spark plug to 20 ft-lb (27 N·m).
Figure 15-1 Spark Plug
A