Ezgo EXPRESS L4 Technician'S Repair And Service Manual Download

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Page L-6

Repair and Service Manual

ELECTRICAL

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

TESTING STARTING CIRCUIT

To prevent the possibility of injury resulting
from vehicle inadvertently starting, disconnect
battery for steps 1 through 8 (see Section “B”).

Tool List

Qty.

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

If the engine will

not

turn over, proceed as following

(Ref. Fig. 1):

1. 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.

2. Check for a blown in line fuse and replace if necessary

with a 7 amp fuse.

3. Check for loose wires at all terminal connections.

4. Check the complete electrical system for correct cir-

cuitry.

5. Inspect for worn insulation or bare wires touching the

frame. Bare wires will cause a short circuit.

6. Check for continuity through the key switch. Set the

DVOM to the ohms (

Ω)

scale. Detach wires. Place

positive (+) probe on one terminal and negative (-)
probe on the other terminal. The reading on the meter
should be “0”

Ω

with the switch key in the

‘

’

posi-

tion and a visual signal (

∞

) with the switch

in the

‘

OFF

’

position. If the meter does not register, replace the
switch. Reconnect the wires.

7. Turn the key switch to

‘

OFF

’.

(a) Place one probe of the DVOM (set to ohms scale)

on the red wire at the solenoid. Place the other
probe on the key switch terminal with the blue wire.

(b) Press the accelerator and observe the DVOM. A

reading of less than 2

Ω

indicates a good limit

switch. A reading of greater than 2

Ω

indicates that

the switch terminals should be checked. A reading
of infinity a visual signal (•) indicates that the switch
must be replaced. Connect the battery.

8. Check the starting solenoid operation. Turn the key

switch to the

‘

’

position.

(a) Place the DVOM (set to the appropriate DC volts

scale) negative (-) probe on terminal “A” of the
solenoid. Place the positive (+) probe on terminal
“B”. The DVOM should indicate approximately 12
V.

(b) Press the accelerator pedal. The DVOM will indi-

cate “0” voltage if the solenoid contacts are closed.

pedal is pressed, replace the solenoid.

TESTING CHARGING CIRCUIT

Tool List

Qty.

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

To prevent the possibility of injury resulting
from vehicle inadvertently starting, the drive
belt must be removed or both rear wheels
raised (see procedure in Section “B”).

The charging circuit consists of a starter/generator, volt-
age regulator and battery (Ref. Fig. 1). The solenoid
must be functional in order to start the vehicle, but is not
considered part of the charging circuit.

1. If the battery charge is inadequate (less than 11 VDC),

proceed as follows:

(a) Check the battery voltage and inspect for loose or

corroded terminal posts and connections. Check
electrolyte level.

(b) Check charging circuit component terminals for

proper, clean, tight connections.

1) Raise the vehicle (see procedure in Section B)

so that both rear wheels are free to rotate.

2) With the engine off, measure the voltage at the

battery’s terminals by placing the negative (-)
probe on the negative (-) post and the positive
(+) probe on the positive (+) post of the battery.
Note the reading.

3) Attach the DC voltmeter across the regulator’s

red and black leads.

4) Start the engine and accelerate to governed

speed.

5) The meter should read higher than before start-

ing the engine. In a reasonable amount of time,
the reading should settle between 14 and 15
volts, indicating the regulator is functioning
properly.

6) If no increase over battery voltage is observed,

there is a malfunction in the charging circuit.

7) If the reading is

above

15 volts, check to

assure the wiring harness and generator field