1993 Club Car won't turn over, solenoid clicks

trainingprof

Just had a tune up including brush replacement in starter. Was doing ok, but would occasionally just die. Depressing the gas pedal again would engage and run fine. Tried to start next AM and nothing but solenoid click.

Troubleshooting so far (in Neutral and maintenance mode):

1. Voltmeter reads 12.7 volts at battery
2. No voltage drop when pedal is pressed, solenoid clicks
3. With solenoid connected, key OFF, continuity good between small posts on solenoid
4. Starter does NOT turn with large posts jumpered with either key ON only, or key ON and pedal pressed.

Bad solenoid?

Dale

BGW

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meimk

Sounds like 2 problems: 1) "occasionally just die", 2)"nothing but solenoid click"
1) By "occasionally just die" do you mean it stalls as you are driving along? or that it sometimes would not start again once you came to a stop. Those are two very different situations.
2) If you've jumped across the two big terminals on the solenoid you have effectively bypassed it, taking it out of the equation. Check for power at the starter generator post with the white wire when the pedal is pressed (and you hear the "click" from the solenoid). Battery voltage there would confirm the solenoid is working correctly and the power wire up to the starter is good. Make sure that terminal is clean & tight. Then check for grounds. I've seen many no starts from a poor ground connection from the starter generator end cap to the frame rail above it. You could even run a jumper wire (large gauge - maybe jumper cable?) from the ground post on the starter to either a good frame ground or even the neg battery terminal itself. If all that checks out you are looking at a starter generator issue. Was there a problem before? You mention starter brush replacement with your recent tune up

trainingprof

Thanks for the reply.
"do you mean it stalls as you are driving along?" Yes. Then it worked fine once I pressed the pedal again. Intermittent and it did NOT do that before I had the tune up and starter brush replacement. After the brush replacement starter/gen was bench checked before reinstall. Drove away from the shop just fine.

"Check for power at the starter generator post with the white wire when the pedal is pressed (and you hear the "click" from the solenoid)." I will do this tomorrow, need additional hands.

"Run a jumper wire (large gauge - maybe jumper cable?) from the ground post on the starter to either a good frame ground or even the neg battery terminal itself." Already installed.

trainingprof

"Check for power at the starter generator post with the white wire when the pedal is pressed (and you hear the "click" from the solenoid)."
Yes, 12+VDC.

I get continuity between the neg post on the battery and the connections to the ground on the starter, but not the post on the starter or the starter casing itself. The only thing left is to disconnect, clean and reconnect all ground cables. Either that, or the starter/gen is

meimk

Sounds like you've found your issue. Sometimes if those get just a little loose they will burn the contacts and lose continuity. They can also build up a little corrosion and lose continuity. Either way it has to have a good ground there and at the "main" ground where the neg battery cable bolts to the frame rail, next to the battery.

trainingprof

100% ground strap issue. Disconnected all things "black" including the case to post cross-over. Checked all cables for end-end continuity (good). Cleaned all cable ends and connection points. Reconnected all cables. Vroom; case closed.

Thanks for your assistance.