First Start After Maintenance

Ningker

Jumped the starter directly. NOTHING.
Pulled it and will look to clean and rebuild it.

Also pulled the solenoid to get replaced. Wanted to replace all the electrical components SO I will pull the micro switches as well.

Just for kicks though, here are the numbers I tested at prior to pulling the solenoid: (Pulled this chart from Land Owner's Post - Sorry, it just made it easier, but THANKS)

List of SOLENOID POLE symbols :
_1 - (#18 Orange) to Limit Switches
_2 - (#18 Blue) to Key
_3 - (#6 Red) to BAT (+) [also #18 Red to FUSE]
_4 - (#6 White) to GEN [also #18 red to VOLTAGE REGULATOR]



List of VOLTAGE readings across SOLENOID POLES:
POLES.............SYS-ON.................SYS-OFF
_1-2..................0.0.........................0.0
_1-3.................Fluctuating...............2.29
_1-4.................11.94......................Fluct uating
_2-3.................Fluctuating...............Fluctu ating
_2-4..................11.97.....................Fluct uating
_3-4..................12.40.....................12.10

BATTERY.............12.73....................12.10


Line VOLTAGES from SOLENOID POLES to TERMINALS of the battery (SYS-ON):
POLE.............BAT (-).................BAT (+)
_1................12.2.......................135.1 ????????
_2................12.25....................Fluctua ting
_3........Fluctuating around 12.......Fluctuating
_4................Fluctuating..........Fluctuating around 12


I do not know what all of this means. Just seems that the numbers are inconsistent and the SOLENOID needs to be replaced.

BTW: A lot of the connections need to be cleaned as they are rusted........

BGW

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shadowman

ok your sure your 10 amp fuse is good?..................................

Ningker

This is one of the first things I replaced with a new one. I ASSUME it is good but I shouldn't huh.
How would I test just the fuse?

shadowman

one thing i have learned with these is never assume.............how are your grounds? engine ground ok?................................

Ningker

Going to head home and clean up all the connections.
Also, if I directly jump or bench test the starter now that it is out it SHOULD turn over if it is OK, yes???
I hope it works so I don't have to tear into the starter.
If it does turn over, should I clean it up since it is out of the cart? Is there a cleaner I can spary it with?

BTW, THANKS to all you guys for your help and especially to you shadowman for your quick responses!!!

fastercarter

Another thing to check while the starter is out is the brushes. These are another common source of non starting issues although they do tend to give some warning of impending failure in most cases, it is not unknown for them to break up and cause issues. You will find them under the four oblong rubber plugs around the circumference at the rear end. Pry out the plugs and you will see a "trigger" type spring that holds them in contact with the commutator. Remove the Phillips head retaining screw that clamps each wire. A bent paper clip or similar is useful to pull back the springs and then the brushes simply pull up out of the guide slots. There is a wear guide indicator etched into each of the brushes and once you get close to or exceed this mark it's time for renewal.
Hope that helps a little,

FC

Ningker

Pulled the brushes and 3 of the 4 are not even close to the etched line. The last one is more worn but still not close to the line. Blew out all the black soot and tried to take the end cap off after removing the two long screws.
It does not want to come out. I was able to get it loose a bit were you can see it detaching from the body, but it just does not want to budge.
Can this be taken off without removing the pulley side?
SHould I pry harder or pound on it some with a rubber mallet?

fastercarter

Yep, it needs to be pried off. Try going in small increments and work your way around slowly. There is a bearing in the tail of the housing that is likely hanging up because of all that carbon dust. Once you get it apart, clean the commutator contacts with some 180 emery paper (an emery board nail file is useful) then when it's nice and shiny, scrape the tip of a golf tee or similar item down each of the slots to remove any of the filings.

FC

shadowman

hey there fastecarter welcome to BGW enjoy and don,t be a stranger......................

fastercarter

Do I know you Tom ?...........

FC