Club Car CARRYALL 252 2007, Maintenance And Service Manual

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TROUBLESHOOTING AND ELECTRICAL SYSTEM:
KEY-START WITH NEUTRAL REV GAS VEHICLE Test Procedures
11
CAP
7
4
3
1
2
5
469
Figure 11-25 Ignition Coil and Cap
470
Figure 11-26 Spark Plug Cap Removal
Ignition Coil – In Vehicle Test
1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL position.
Chock the wheels.
2. Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline Vehicles, Section
1, Page 1-3.
3. Using a multimeter set to 200 ohms, measure the primary coil resistance.
3.1. Disconnect both of the bullet terminals at the RPM limiter (Figure 11-22, Page 11-23) . Place the red (+)
probe of the meter on the male bullet terminal of the wire connecting to the ignition coil under the fan
housing, and place the black (–) probe on a clean unpainted surface of the engine or frame
(Figure
11-23, Page 11-24) .
3.2. If the resistance is not between 0.6 - 1.7 ohms, bench test the ignition coil.
4. Using a multimeter set to 20k ohms, measure the resistance of the secondary coil and spark plug cap together.
4.1. Place the red (+) probe of the meter into the end of the spark plug cap that normally connects to the spark
plug and place the black (–) probe on a clean unpainted surface of the engine or frame (Figure 11-24,
Page 11-24) .
4.2. If the resistance is between 12.0k - 14.0k ohms, the secondary coil and spark plug cap are within
acceptable limits; proceed to step 7. If the resistance is not between 12.0k - 14.0k ohms, the spark plug cap
and secondary coil must be tested independently from each other.
5. Test the spark plug cap separately from the secondary coil.
5.1. Remove the rubber gasket (1) on the plug cap (2) by rolling back the gasket onto the spark plug wire (3)
(Figure 11-25, Page 11-25) .
5.2. Remove the cap from the wire by turning the cap counterclockwise three or four revolutions while gently
pulling it off the wire (Figure 11-26, Page 11-25) .
5.3. Using a multimeter set to 20k ohms, place the red (+) probe of the multimeter into the end of the spark plug
cap that normally connects to the spark plug and place the black (–) probe into the end of the cap with the
internal screw
(Figure 11-27, Page 11-26) . If the resistance is not between 4.5k - 6.0k ohms, the cap has
failed and must be replaced. Proceed to the next step with the spark plug cap still removed.
6. Test the secondary coil separately from the spark plug cap.
6.1. Using a multimeter set to 20k ohms, place the red (+) probe of the meter into the end of the spark plug wire
and place the black (–) probe on a clean unpainted surface of the engine or frame (Figure 11-28, Page
11-27) . If the resistance is between 6.0k - 11.0k ohms, the secondary coil is within acceptable limits. If the
resistance is not between 6.0k - 11.0k ohms, bench test the ignition coil.
7. If the preceding procedures indicate that the ignition coil resistance readings are within acceptable ranges, but
the coil fails to function properly, proceed to the following bench test procedures.
2007-2009 Turf 252, Carryall 252 and XRT 900 Maintenance and Service Manual Page 11-25