Club Car XRT 800 Maintenance Service Manual page 223

ELECTRICAL COMPONENTS: 800 AND 810 GASOLINE VEHICLES
10
Remove
Figure 13-24 Remove Fan Housing
Ignition Coil Installation
NOTE: If a new ignition coil is being installed, the spark plug cap, gasket, protector tube and grommet
must be removed from the old coil and installed on the new coil. See steps 1 through 8 for pro-
cedures to remove and install these existing parts.
If the existing ignition coil will be remounted, proceed to step 9.
1. Remove the rubber gasket (1) on the plug cap (2) by rolling back the gasket onto the spark plug wire.
2. Remove the cap (2) from the wire by turning the cap counterclockwise three or four revolutions while
gently pulling it off the wire (Figure 13-26, Page 13-26).
3. Remove the gasket (1) and protector tube (3) from the old coil. See following NOTE.
NOTE: Moisten the spark plug wire with water to make gasket removal and installation easier.
4. Remove the grommet (4) from the old spark plug wire. Clean the grommet and place it on the new spark
plug wire (5).
5. Install the protector tube (3) onto the new wire (Figure 13-26, Page 13-26).
6. Slide the gasket (1) onto the end of the new spark plug wire.
7. Install the cap (2) on the new coil spark plug wire by rotating it clockwise three or four revolutions while
applying light pressure on the cap.
8. Install the gasket (1) on the cap (2).
9. Position the ignition coil (7) onto the cast mounting bosses on the engine crankcase and tighten the two
mounting bolts (6) finger-tight.
10. Rotate the flywheel (8) until the magnet is positioned directly under the ignition coil. Use a 0.012 inch
(0.304 mm) bronze feeler gauge to set the air gap between the ignition coil and the flywheel magnet.
Tighten the two mounting bolts (6) to 30 in-lb (3.4 N·m) (Figure 13-27, Page 13-26).
11. Connect 18-gauge black (12) wire to the spade terminal (13) on the coil (Figure 13-25, Page 13-25).
12. Position the fan housing close to the engine crankcase and slide the plug wire grommet into the notch
on the housing.
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6
5
8
2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual
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13
11
Figure 13-25 Black Wire and Ignition Coil
13
Ignition Coil
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Page 13-25