Club Car Cafe Express Maintenance And Service Manual page 118

11
Troubleshooting Guide
TROUBLESHOOTING GUIDE
SYMPTOM
Spark plug fouls repeatedly.
Starter fails to operate.
Starter/generator does not charge battery.
TABLE CONTINUED ON NEXT PAGE
Page 11-6 2018 Café Express Maintenance and Service Manual
POSSIBLE CAUSES
Incorrect plug
Spark plug wire is damaged
Unsuitable fuel, or incorrect (rich) fuel mixture
Ignition coil failed
Dirt entering combustion chamber
Rings are heavily worn, low cylinder pressure
Neutral lockout switch is in the MAINTENANCE
position
Fuse is blown
Battery is dead
Starter control circuit is not operating
Starter/generator failed
Starter solenoid failed
Accelerator pedal limit switch failed
Key switch failed
Neutral lockout limit switch failed
Loose or broken wire in starter/generator
circuit
Cylinder and/or crankcase flooded with fuel
Loose or broken wire in the starter/ generator
circuit
Generator field coil is shorted
Brushes are worn or commutator is dirty
Starter/generator belt is loose or slipping
Voltage regulator failed
Battery failed
TROUBLESHOOTING AND ELECTRICAL
SYSTEM: PEDAL-START GAS VEHICLE
CORRECTIVE ACTION
Section 13 — Engine (Subaru EX40)
Section 13 — Engine (Subaru EX40)
Section 14 — Fuel System: Gasoline Vehicles
Test Procedures 15 – Ignition Spark and 16
– Ignition Coil
Check intake system for leaks.
Section 14 — Fuel System: Gasoline Vehicles
Section 13 — Engine (Subaru EX40)
Place switch in the OPERATE position.
Test Procedure 2 – Fuses
Test Procedure 1 – Battery
Test Procedure 5 – Key Switch (Start Circuit)
Test Procedure 12 – Starter/Generator (Starter
Function)
Test Procedure 8 – Solenoid
Test Procedure 7 – Accelerator Pedal Limit
Switch – Pedal-Start Vehicles Only
Test Procedure 5 – Key Switch (Start Circuit)
Test Procedure 10 – Neutral Lockout Limit
Switch – Pedal-Start Vehicles Only
Section 12 — Electrical Components:
Pedal-Start Gas Vehicle Starter/Generator on
page 12-1
Section 14 — Fuel System: Gasoline Vehicles
Test Procedure 11 – Starter/Generator
(Generator Function)
Test Procedure 11 – Starter/Generator
(Generator Function)
Section 12 — Electrical Components:
Pedal-Start Gas Vehicle Starter/Generator on
page 12-1
Section 12 — Electrical Components:
Pedal-Start Gas Vehicle Belt Tension
Adjustment for EFI Engines on page 12-13
Test Procedure 13 – Voltage Regulator
Test Procedure 1 – Battery