Club Car IntelliTach XRT 1550, Maintenance And Service Manual

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TROUBLESHOOTING AND ELECTRICAL SYSTEM: KAWASAKI POWERED GASOLINE VEHICLES Test Procedures
2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 11a-27
11A
4. Adjust tester probes to approximately 18,000 volts (18 Kv), setting (SE – Small Engine Setting on the
Thexton 404 tool). Connect tester to spark plug wire and connect alligator clip to a solid engine ground.
5. If there is a strong blue spark between the probes of the spark gap tester, stop the engine and perform
the test on the remaining spark plug.
6. There should be a strong blue spark between the probes of the spark gap tester when both spark plug
circuits are tested. If there is no spark on either of the ignition circuits, or if either of the sparks is a faint
yellow or red color, test the ignition circuit components.
See the Kawasaki FH680D engine manual
(CCI P/N 103351201).
7. If the spark gap tester tool indicates a strong blue spark, it is possible the spark plug has failed internally.
Install a new spark plug set to the proper gap setting and test the engine for proper operation. See Spark
Plugs, Section 10b, Page 10b-12.
TEST PROCEDURE 16 – ENGINE KILL WIRE
See General Warning, Section 1, Page 1-1.
1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock
the wheels.
2. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in
General Warning, Section 1, Page 1-1.
3. Disconnect the six wire engine harness connector located near the starter (Figure 11a-23,
Page 11a-27) .
4. Connect the red (+) probe of the multimeter to the white/black wire terminal of the six wire connector and
connect the black (–) probe to the vehicle frame (ground). The multimeter should indicate continuity with
the key switch in the OFF position.
5. With the Forward/Reverse handle in the NEUTRAL position, insert the key and turn the key switch to the
ON position. Note the multimeter reading. Turn the key and hold it in the START position. Note the mul-
timeter reading.
6. There should be no continuity when the key switch is in the ON or START position. If continuity is indi-
cated, check for worn insulation on the white/black wire that grounds the wire to the frame. See Test Pro-
cedure 17 – Grounded Kill Wire on page 11a-28. Also check the key switch for proper operation. See
Test Procedure 18 – Key Switch (Engine Kill Circuit) on page 11a-28.
Figure 11a-23 Engine Harness Connector Figure 11a-24 Engine Kill Wire