Club Car 2007 Carryall 295 Maintenance And Service Manual page 223

TROUBLESHOOTING AND ELECTRICAL SYSTEM: HONDA POWERED GASOLINE VEHICLES
TEST PROCEDURE 14 – VOLTAGE REGULATOR
See General Warning, Section 1, Page 1-1.
NOTE: Keep the battery connected during this test procedure.
1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock
the wheels.
2. Ensure that the wires are connected correctly and are tight. If they are not, rewire or tighten as necessary.
3. Check the engine RPM setting to ensure that it is adjusted correctly. See Engine RPM Adjustment,
Section 13b, Page 13b-23.
4. With the battery in good condition and fully charged, run the engine for several minutes to bring the volt-
age regulator to operating temperature.
5. Set the multimeter for 20 VDC.
6. With the engine running at full-governed RPM, measure the battery voltage at the battery posts. If the
reading is between 14.0 and 15.0 volts, the regulator is good. If the reading is lower than 14.0 volts but
rising steadily, check the battery condition. See Test Procedure 1 – Battery on page 11b-9.
7. If the reading is less than 14.0 volts and not rising, check the charge coil. See Test Procedure 13 –
Charge Coil on page 11b-26. Also check for a loose connection at the voltage regulator multi-pin con-
nector and check the continuity of each wire in the voltage regulator multi-pin connector.
8. If the reading is more than 15.0 volts and continues to rise, replace voltage regulator. See Voltage Reg-
ulator Removal, Section 12b, Page 12b-3.
TEST PROCEDURE 15 – IGNITION SPARK
See General Warning, Section 1, Page 1-1.
NOTE: Keep the battery connected during this test procedure.
1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock
the wheels.
2. Remove the spark plug wire from one of the spark plugs.
3. Use an ignition spark gap test tool (Thexton 404 or equivalent) to check for correct spark.
4. Adjust the tester probes to approximately 18,000 volts (18 Kv), setting (SE – Small Engine Setting on the
Thexton 404 tool). Connect the tester to the spark plug wire and connect the 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 Honda GX620 engine manual (CCI P/
N 102615401).
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 the
Honda GX620 engine manual (CCI P/N 102615401).
2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual
11B
Test Procedures
Page 11b-27