Club Car Cafe Express Maintenance And Service Manual page 145

TROUBLESHOOTING AND ELECTRICAL
SYSTEM: PEDAL-START GAS VEHICLE
TEST PROCEDURE 15 – Ignition Spark
See General Warnings on page 1-1.
NOTE: Keep the battery connected while performing this test procedure.
1. If necessary, see Testing Basics on page 11-14.
2. Place the Forward/Reverse handle in the NEUTRAL position and the neutral lockout switch in the MAINTENANCE
position. Chock the wheels.
3. Remove the plug wire from the spark plug. Using an ignition spark gap test tool (Thexton 404
check for correct spark (Figure 11-17, Page 11-33).
3.1. 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.
3.2. Start the engine. There should be a strong blue spark between the probes of the spark gap tester. If
there is no spark, or if the spark is a faint yellow or red color, test components of the ignition circuit. See
Ignition Coil on page 11-34.
4. If the spark gap tester tool indicates a strong blue spark, it is possible the spark plug has failed internally. Check
the spark plug gap. The gap should be set at 0.024 to 0.028 in. (0.6 to 0.7 mm). If the gap is correct, replace
the spark plug with a new part and test the engine for proper operation.
1. Ignition Gap Test Tool 2. Chassis
464
1
Figure 11-17 Ignition Spark Test
2018 Café Express Maintenance and Service Manual
11
Test Procedures
® or equivalent),
Page 11-33