Club Car Carryall 1500 Maintenance And Service Manual page 164

11
Test Procedures
TEST PROCEDURE 21 – Ignition Spark
See General Warnings, Section 1, Page 1-2.
NOTE: Keep the battery connected during this test procedure.
1. Disable the vehicle. See Disabling the Vehicle on page 1-3.
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 tester probes to approximately 18,000 volts (18 kV), setting (SE – Small Engine Setting on the Thexton
404 tool). Connect tester to spark plug wire and connect 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 Kawasaki FH680D engine manual (CC P/N 103351201).
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 Spark Plugs,
Section 10, Page 10-15.
TEST PROCEDURE 22 – Engine Kill Wire
See General Warnings, Section 1, Page 1-2.
1. Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline/Diesel Vehicles on
page 1-3.
2. Disconnect the six wire engine harness connector located near the starter (Figure 11-23, Page 11-29).
3. Connect the red (+) probe of the multimeter to the white/black wire terminal of the six wire connector and
connect the black (–) probe to the vehicle frame (ground). The multimeter should indicate continuity with the
key switch in the OFF position.
4. With the Forward/Reverse handle in the NEUTRAL position, insert the key and turn the key switch to the ON
position. Note the multimeter reading. Turn the key and hold it in the START position. Note the multimeter reading.
5. There should be no continuity when the key switch is in the ON or START position. If continuity is indicated,
check for worn insulation on the white/black wire that grounds the wire to the frame. See Test Procedure 23 –
Grounded Kill Wire on page 11-29. Also check the key switch for proper operation. See Test Procedure 24 –
Key Switch (Engine Kill Circuit) on page 11-30.
Page 11-28 2015 Carryall 1500/1700 and XRT 1550 Maintenance and Service Manual
TROUBLESHOOTING AND ELECTRICAL
SYSTEM: GASOLINE VEHICLES