EZ-GO ST 4X4 Technician'S Repair And Service Manual Download

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ELECTRICAL

Page G-4

Repair and Service Manual

Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

TESTING STARTING CIRCUIT

To prevent the possibili-
ty of severe injury or
d e a t h r e s u l t in g f ro m

vehicle inadvertently starting, disconnect battery for
steps 2 through 9 (see Section B).

If any DVOM readings indicate a faulty wire, it
is recommended that the condition of the termi-

nals and wire junction be examined. A faulty wire should be
replaced with one of the same gauge and color and wired
between the correct components and wire tied to the harness
bundle. The faulty wire should be cut back close to the harness
and the ends protected with vinyl electrical tape.

Most DVOM’s can be set to give an audible signal if continuity
is present, however readings will generally indicate near

Ω.

Readings greater than 1K

Ω

may indicate a marginal conductor

or joint.

Tool List

Qty. Required

DVOM.......................................................................... 1

If the engine does not rotate, proceed as follows:

1. Check for a good ground between the battery nega-

tive (-), the frame and the engine.

2. Check that vehicle is in neutral (Ref Fig. 1 on page G-

1).

3. Check the battery for a voltage reading which should

be between 12.2 and 12.5 volts. Inspect for loose or
dirty battery post connections.

4. Check for a blown in line fuse and replace if neces-

sary with the recommended amp fuse.

5. Check for loose wires at all terminal connections.

6. Check the complete electrical system for correct cir-

cuitry.

7. Inspect for worn insulation or bare wires touching the

frame. Bare wires will cause a short circuit.

8. Set the DVOM to the ohms (

Ω)

scale. A meter read-

ing of “0”

Ω

indicates continuity. Check for continuity

for white (WHT) wire from battery positive terminal (+)
to the key switch terminal (B) white (WHT) wire. If
continuity is not indicated, there is a fault in the wiring
harness. Check for continuity of the key switch.
Remove key switch plate from instrument panel (Ref
Instrument Panel Replacement section in BODY AND
TRUCKBED). Detach electrical plug from key switch.
Place positive (+) probe on terminal (B) of white
(WHT) wire and negative (-) probe on terminal (S) of
black/white (BLK/WHT) wire. The reading on the

meter should be “0”

Ω

with the switch key in the ‘ON’

position and OL with the switch in the ‘OFF’ position.
If the meter does not register, replace the switch.
Reconnect the wires.

9. Turn the key switch to ‘ON’.

•

Set the DVOM to the ohms (

Ω)

scale and place

one probe on the black/white (BLK/WHT) at the
solenoid. Place the other probe on the key switch
terminal (S) with the black/white (BLK/WHT). If
continuity is not indicated check for continuity at
the neutral switch. If continuity is not indicated,
replace neutral switch. If continuity is indicated
check wiring between key switch (S) and neutral
switch and between neutral switch and starter
solenoid. If continuity is indicated, the starter sole-
noid must be checked.

10. Check the starting solenoid operation. Turn the key

switch to the ‘OFF’ position.

a) Place the DVOM (set to appropriate DC

volts scale) positive (+) probe on the ter-
minal with the black/white (BLK/WHT)
wire solenoid. Place negative (-) probe on
to ground.

b) The DVOM should indicate reference

battery voltage (approximately 12 V).

c) Turn the key switch to the ‘OFF’ position.

The DVOM should indicate 0 V.

d) Replace solenoid if 12 V is not indicated

with the switch turned to ‘ON’.

BATTERY VOLTAGE TEST

Hydrogen gas formed
during battery charging
i s e x p l o s i v e a n d c a n