Circuits And Controls; Starter; Generator; Wiring - E-Z-GO FLEET 1999 Technician's Repair And Service Manual

ELECTRICAL
Read all of Section Band this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

CIRCUITS AND CONTROLS

The electrical system is a 12 volt negative ground system
(Ref Fig. 1 on page K-2) (Ref Fig. 2 on page K-3) consist­
ing of a:
• battery
• starter/generator
• voltage regulator
• solenoid
• ignitor
• ignition coil
• accelerator limit switch
• fuse
• key switch
• pulser coil
AwARNINGA
ing starter/generator or engine to rotate must be per­
formed with the rear wheels raised (see Section "B'J
or the neutral lock engaged (see Section "A'J.
To reduce the possibility of personal injury, follow the
lifting procedure in Section "B" of this manual. Place
wheel chocks in front of and behind the front wheels.
Check the stability of the vehicle on the jack stands
before starting any repair procedure. Never work on a
vehicle that is supported by a jack alone.

STARTER

When starting the engine, the field coils are in series with
the armature and the starter/generator operates as a
motor (Ref Fig. 1 on page K-2). This circuit is controlled
by a key switch, fuse, accelerator limit switch and a sole­
noid. With the key in the 'ON' position, battery current is
available to the accelerator limit switch which remains
open until the accelerator pedal is pressed. When the
pedal is pressed, the plunger on the switch is released,
the contacts close and the ignition circuit is energized.
Battery current then energizes the solenoid which closes
the contacts and energizes the starter circuit. The starter/
generator now functions as a starter to start the engine.

GENERATOR

When the engine is running, the starter/generator func­
tions as a generator. This is used for charging the battery
and for the ignition system. Generated output is con­
trolled by the voltage regulator at 14.25 - 14. 75 V, without
regard to engine speed. However, the charging current
To prevent inadvertent
movement of vehicle, all
tests performed requir­
Repair and Service Manual
will vary depending on the condition of the battery. If it is
fully charged, current is controlled at 3 to 5 amps.

WIRING

AwARNINGA
battery cables from the battery posts (see procedure
in Section "B").
Electrical tests of the wiring for continuity may be made
with a DVOM (Digital Volt Ohm Meter) available through
the E-Z-GO Service Parts Department (E-Z-GO P/N
27 481-G01 ). Any DVOM may be used, however the con­
trols, displays and features may vary depending on the
make and model. Set the meter selector to the ohms
scale and check continuity between each circuit compo­
nent as indicated. Example: If a switch is open or if there
is a break in the wiring, the meter will display a visual sig­
nal. If an analog meter is used it will read infinity ( 00 ).

TESTING IGNITION CIRCUIT

NOT E
I � hi � section assumes t ? e � uel sy � t � m is tune-
I
.
- tJoning and that the engine 1s receiving fuel.
Tool List
DVOM .......................................................................... 1
Spark plug (NGK BPR4ES) ......................................... 1
Spark plug tester ......................................................... 1
AwARNINGA
tion system is disabled. Fuel drawn into the cylinders
will be expelled through the spark plug opening and
could be ignited by the ignition system or another
source, resulting in a fire.
The engine incorporates a solid state ignition system that
fires both plugs simultaneously. There is no distributor.
The engine can be stopped by turning the key switch to
the 'OFF' position. When the accelerator pedal is
released, the limit switch contacts open and the ignition
circuit is de-energized.
CAU T I ON
Do not arc spark plug wire to ground.
Connect to a known good spark plug
and ground plug to a clean metal surface (muffler, cylinder, etc.).
Permanent damage may be caused to the coil or ignitor if the
plug is not grounded properly.
K
Before performing any
test of wiring compo­
nents, disconnect the
Qty. Required
Never operate the starter
unless both spark plugs
are installed or the igni­
Page K-1