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Unread 09-20-2010, 02:14 PM   #1
Not Yet Wild
 
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Default Starter/Generator Failure

I have a 98 club car DS gas.
My original starter failed because a field winding buss strip broke I assumed because of vibration. I repaired that by soldering a wire bridge to it. Starter worked but failed after 15 minute ride. Opened and found it burnt in vicinity of repair. Installed a new field winding. Bench Tested and worked, installed in cart and worked for 15 min. and failed. On the contact end of the armature (commutator?) one of the brass contacts loosened and wiped out the brushes. Believing that it was mechanical failure I tried again with a new starter. I Installed it and started and stopped it several times all O.K. Went for a 10 minute test ride and the starter failed again. I believe the brushed failed because of carbon bits and a tiny piece of brass came out of inspection ports.

I need some help! It is getting really expensive. Could voltage regulator cause these types of failure? Any input will be greatly appreciated. I believe after three tries something else is wrong.

This is my first post. Thanks.
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Unread 09-20-2010, 06:00 PM   #2
The Last Moja Morani
 
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Default Re: Starter/Generator Failure

i,m not sure what the voltage regulator will do to the starter if its overcharging..........some voltage regs, when they fail they over charge........i have seen them charge up to 18 volts but anything over 15.3 is a bad regulator, when you solder anything in there you should use silver solder and also i,m not sure if that year had clockwise motors and counter clockwise motors which call for different parts even brushes are different..............................
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Unread 09-20-2010, 08:30 PM   #3
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Default Re: Starter/Generator Failure

you got a new starter, from where? Was it one of those off Ebay? I would check the voltage regulator, but I doubt that would cause the failure, I have seen many that charge the battery to the moon and never took out the starter, I'd look at other issues.
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Unread 09-20-2010, 10:36 PM   #4
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Default Re: Starter/Generator Failure

You are right. The latest starter was an aftermarket starter. You state I should look at other issues. Is there somewhere else to look other than voltage regulator and starter?

Thanks, Chuck
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Unread 09-20-2010, 10:40 PM   #5
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Default Re: Starter/Generator Failure

Could installing the jumper wire on the wrong starter terminals cause this type of failure?
I don't think I installed it wrong but I do not know for sure.
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Unread 09-21-2010, 11:45 AM   #6
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Default Re: Starter/Generator Failure

I don't believe you can kill one of those generators that quick running full field. These are heavy generators and I don't think it would over heat that quick. Do you see any other signs of over heating in the generator? I don't think hooking it up wrong will do what you are experiencing.

You may want to read this thread on generators. It is long and much of it may not apply to your situation, but, you will find lots of good reference & test info on club car generators.

Generator 101
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Unread 09-21-2010, 12:26 PM   #7
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Default Re: Starter/Generator Failure

I appreciate all the responses. No, there doesn't seem to be edxtensive overheating in the units. I'm just wondering if I should get a new voltage regulator before I install another new starter? I'm leaning towards "yes" because it is to coincidental to wipe out three in a row without some issue down the line causing it. I'm wondering if MURPHY'S LAW is covered in GENERATOR 101?
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Unread 09-21-2010, 05:24 PM   #8
The Last Moja Morani
 
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Default Re: Starter/Generator Failure

check your charging system at the voltage regulator, put cart in maintence mode than with your voltage meter red probe on pos of batt. black on neg. of batt. start cart up and watch meter if it rises up past 15.3 i would replace it ..........its bad and a lot cheaper than a starter........if this is the case drive cart see if you burn up another starter .....................let us know either way.......................................
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Unread 09-21-2010, 07:26 PM   #9
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Default Re: Starter/Generator Failure

It dies in 15 minutes...big red flag there, that whatever it is, somehow wipes out a starter motor in that amount of time. Ive seen voltage regulators charge over 17 volts and not take out the starter, something is up, It just needs a closer look once you have it running again.
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Unread 09-21-2010, 08:58 PM   #10
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Default Re: Starter/Generator Failure

I have ordered a replacement starter. I looked at the old starter and I did connect the wires incorrectly. I had A-2 to ground, and the jumper went from A-1 to F-1. I am pretty sure that it was this way for the last two attempts. I will let the BUGGIES GONE WILD community know if this was the reason the brushes and commutator self destructed. No one else needs to make the same costly mistake.
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