Club Car Cafe Express Maintenance And Service Manual page 142

11
Test Procedures
• When disconnecting wires from starter/generator terminals, use a second wrench on the lower nut of
the terminal post to hold post steady.
• Scrape a small amount of paint from starter/generator housing (ground) and use this location when testing
motor terminals to electrical ground.
_
MOTOR TERMINALS
A1 to A2
F1 to F2
A1 to F1
A1 to F2
A2 to F1
A2 to F2
A1 to Ground
A2 to Ground
F1 to Ground
F2 to Ground
1. If necessary, see Testing Basics on page 11-14.
2. Disconnect battery and spark plug wire(s). See Disconnecting the Battery-Gasoline Vehicles on page 1-3.
3. Disconnect the wires from all the terminals on the starter/generator. Then place the black (–) probe of a
multimeter, set to 200 ohms, on the starter/generator housing (scratch through the finish to ensure a good
ground). While holding the black (–) probe against the housing, place the red (+) probe (one at a time) on the A1,
A2, F1, F2 and DF terminals respectively (Figure 11-14, Page 11-29). The readings should be no continuity. If
the readings are incorrect, the starter/generator will need to be removed from the vehicle and disassembled by a
qualified technician. See Starter/Generator Removal on page 12-1.
– An incorrect reading from the A1 or A2 terminal indicates three possible problems: 1) a grounded A1 or A2
terminal, 2) a grounded wire in the brush area, or 3) a grounded armature/commutator.
– If the F1 or F2 reading is incorrect, it indicates a possible grounded F1 or F2 terminal or a grounded field coil.
– If the DF reading is incorrect, it indicates a possible grounded DF terminal or a grounded field coil.
4. Using a multimeter set to 200 ohms, place the red (+) probe on the A1 terminal and the black (–) probe on the A2
terminal. The reading should be continuity. If the reading is incorrect, a possible open or poor contact in a brush
assembly and/or open armature windings may be the cause. The starter/generator will need to be removed from
the vehicle and disassembled by a qualified technician. See Starter/Generator Removal on page 12-1.
5. With the wires still disconnected, using a multimeter set on 200 ohms, place the red (+) probe on the F1 terminal
and the black (–) probe on the F2 terminal. The reading should be between approximately 0.1 and 0.3 ohms. If
the reading is incorrect, a possible open field coil or bad connections at terminals may be the cause. The
starter/generator will need to be removed from the vehicle and disassembled by a qualified technician. See
Starter/Generator Removal on page 12-1.
6. With the wires still disconnected, using a multimeter set to 200 ohms, place the red (+) probe on the DF terminal
and the black (–) probe on the F1 terminal. The reading should be between 4.5 and 5.5 ohms. If the reading is
incorrect, a possible grounded DF terminal and/or grounded field coil may be the cause. The starter/generator
will need to be removed from the vehicle and disassembled by a qualified technician. See Starter/Generator
Removal on page 12-1.
Ensure that wires are connected correctly and are tight. If they are not, rewire or tighten as necessary.
Page 11-30 2018 Café Express Maintenance and Service Manual
CONTINUITY TEST
RESULT
Continuity
No Continuity
No Continuity
No Continuity
No Continuity
TROUBLESHOOTING AND ELECTRICAL
SYSTEM: PEDAL-START GAS VEHICLE