Club Car Carryall 300 2021, Maintenance And Service Manual

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Electrical System
56 17 690 15 Rev. -- KohlerEngines.com
Troubleshooting Guide
Test Ignition System
Isolate and verify trouble is within engine.
1. If Kohler diagnostic software is available, review "Safety System Active" status in Data Display screen. If yes is
displayed, equipment safety circuit is active (Refer to equipment manufacturer's manual for safety system
information). This must be corrected prior to continuing testing.
Condition Possible Cause Conclusion
Problem goes away. Electrical System Check key switch, wires,
connections, safety interlocks, etc.
Problem persists. Ignition or Electrical System Inspect wiring harness (primary and
secondary) for any obvious issues.
Testing of ignition coil is required.
Refer to EFI System, Ignition Coil
Testing for details.
Test for Spark
NOTE: Do not crank engine or perform tests with spark plug lead disconnected and not grounded, or permanent coil
damage may occur.
1. With engine stopped, disconnect spark plug lead. Connect spark plug lead to post terminal of spark tester and
attach tester clip to a good engine ground.
2. Crank engine over, establishing a minimum of 550-600 RPM, and observe tester for spark.
Condition Possible Cause Conclusion
Cylinder is not fi ring or has
intermittent spark.
Wiring, Connections,
or System Power
Using a DVOM, attach black (-) lead of meter to battery
ground, remove primary plug from coil, test voltage at red
wire with black tracer at coil primary connector with ignition
key ON. Battery voltage should be seen. If no voltage, check
all fuses. Key OFF, perform continuity test between black
primary wire connector and corresponding pin terminal 1 on
black ECU connector (refer to EFI System Wiring Diagram).
If no continuity is found, repair or replace electrical wiring
harness. If continuity is found, refer to EFI System, Ignition
Coil Testing, test circuit (power and ground). Repair/replace
as needed. Test ignition coil and connection. Refer to Test
Ignition System (above).
Tester shows spark but
engine misses or won’t run.
Spark Plug Try new spark plug.
Flywheel Key Remove fl ywheel, inspect key, replace key if damaged.
No spark. Ignition Switch, EFI
System, Kill Lead
Test for "Safety System Active" as described in step 1 of Test
Ignition System (above). Inspect red 10 amp fuses. Replace
fuse if found blown. If fuse is OK, using a DVOM, attach
black (-) lead of meter to battery ground, key ON, test for
voltage at 2 red 10 amp fuses. Battery voltage should be
seen on both sides of fuses. If voltage is found on 1 side of
fuse only, inspect for blown fuse or inspect fuse holder/
terminals for arching or corrosion. If no voltage is seen at any
fuse, further electrical testing inspection is required
(application, key switch, ground connections, etc.) Recheck
position of ignition switch and check for shorted kill lead.
Good spark but engine
runs poorly or existing plug
condition is questionable.
Spark Plug Install new spark plug and retest engine performance.
Flywheel Key Remove fl ywheel, inspect key, replace key if damaged.