08-02-2014, 09:46 AM | #1 |
Not Yet Wild
Join Date: Jul 2014
Location: columbus ohio
Posts: 29
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testing 3 way key switch on a harley cart
I have what looks to be from the wiring diagrams a 1990 or newer harley golf cart 2 cyc gas.
I was rebuilding the carb and fuel pump and after i got it together the cart would not turn over all of a sudden. Got frustrated and went to close the body and drove a screw driver through the key switch. Didn't have a key at the time was using a screw driver to turn switch. I ordered a new switch installed it and the wires where already number so i know they are on right.still does nothing. after looking into it more i found a wire off that came from the breaker.Now i have the solenoid clicking and and i have installed a new starter gen. When i put a meter on the ger. i am getting voltage on all the posts gen. does not move. I tested the gen. it works through the tests.I am thinking the new key switch is bad is there a way to bypass the switch to make sure it is bad before i drop another 100 on a new one? Or is there a way to test the switch? I see there is 3 diodes one on the key switch could that be causing the trouble if there bad? help need to get this running in less then 3 weeks for vacation thanks all |
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08-02-2014, 10:09 AM | #2 |
Gone Wild
Join Date: Jul 2008
Location: Reddick IL
Posts: 11,220
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Re: testing 3 way key switch on a harley cart
If the solenoid is clicking I would check the state of charge on the battery.
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08-02-2014, 10:31 AM | #3 |
Not Yet Wild
Join Date: Jul 2014
Location: columbus ohio
Posts: 29
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Re: testing 3 way key switch on a harley cart
battery full charge getting 12 volt at the battery and on all terminals of the starter generator? tested miro switch and solenoid. the old starter looked like it tryed to move when i pulled a cover and looked into the brushs so i ordered a new starter generator still same thing thats when i tested voltage on all leads one should be neg ??
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08-02-2014, 11:42 AM | #4 |
Not Yet Wild
Join Date: Jul 2014
Location: columbus ohio
Posts: 29
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Re: testing 3 way key switch on a harley cart
when i say tested voltage i had neg lead on the battery pos lead touched all wires on starter and read 12 volts should not one leg been neg reading 0 ?
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08-03-2014, 04:16 PM | #5 |
Gone Wild
Join Date: Jul 2014
Location: St. Paul Minneapolis MN USA
Posts: 522
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Re: testing 3 way key switch on a harley cart
You say 'the solenoid'? If its only got one solenoid its a fairly complicated switch. The small wire part is only got +'s on it but the fat wire part actually handles the forward and reverse switching for the starter so its got both + and - in it all the times, its just different combinations depending on the direction selected.
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08-03-2014, 07:45 PM | #6 |
Not Yet Wild
Join Date: Jul 2014
Location: columbus ohio
Posts: 29
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Re: testing 3 way key switch on a harley cart
me and my good friend figured that out but a switch is just certain wires connected in a certain senescence so wondered if any one knew which lol i am about to figure that out in the next 4 days ill post a reply on how it works lol after how many fuses we do not no yet
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08-04-2014, 08:03 AM | #7 |
Gone Wild
Join Date: May 2011
Location: Pittsburgh
Posts: 2,943
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Re: testing 3 way key switch on a harley cart
I don't believe Harley made carts in the 90s. Are you sure you have the right wiring diagram?
The three diodes right there on the switch is odd. I thought there was only one there and couple of more farther down in the circuit but I have never worked on anything newer than '85. Unfortunately, there is no way to jump those switches. Every part of that cart's circuit runs through that cart. It was a bad idea but it is what it is. Those switches aren't "on/off" like most are. All of those wires at the back of that switch are grouped very tightly. It's very, very easy, to have wires touching each other there and shorting things out. Double check that and add some insulation between the wires if need be. I had to grind the edges of some those wire connectors to get them to fit onto new switches without touching each other. Without knowing what year cart you have, there should be a micro-switch under the driver's side floor that activates when you press the accelerator. That one can be jumped. If that is bad nothing you do with that cart will make it run. |
08-04-2014, 10:50 AM | #8 |
Gone Wild
Join Date: Jul 2014
Location: St. Paul Minneapolis MN USA
Posts: 522
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Re: testing 3 way key switch on a harley cart
Loclin, does your 85 still have the Harley badges on it? Or did they go to the par car by then?
82-95 they used the 'heavy duty' key switch that switched both the small wire circuits and the fat wire circuit that went direct to the starter/gen. Earlier cts used a separate key for security and a master on/off and then a floor mounted forward reverse for the big wires to the starter. The 82-95 switches were barely strong enough for the job. They only had medium duty contacts and they jammed em into a very small package. Because of their size and location it was also common for operators to turn the key while the cart was still moving which caused arching. The arcing is very bad thing for a switch that could barely handle the load when it was new. Some other carts in the 80's and 90's had a multi solenoid arrangement for the for the heavy duty switching so all the key did is select which solenoids operated. Where it gets confusing is because of the crappy expensive switch many people converted to the multi solenoid or partially converted. That's where it gets difficult to trouble shoot since there are multiple ways to do it. |
08-04-2014, 11:39 AM | #9 |
Gone Wild
Join Date: May 2011
Location: Pittsburgh
Posts: 2,943
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Re: testing 3 way key switch on a harley cart
The framed is badged as a Harley (HD serial # plate). There isn't anything on the body. I saw some list somewhere that said that '85 was the final year for anything HD. The electronic ignitions started with '86 thus officially ending the "old school" HD / Columbia line.
You'll notice in those manuals that the voltage regulator on the '82-'84 is wired just a bit differently than the voltage regulator on the '85. Mine will only charge the battery with the '85 configuration so I am pretty sure on the year. However, I thought that the '85 also had the oil injector which mine doesn't have. My hunch is that, at some point in the past, someone put two carts together to make this cart. I will be picking up an '82 3 wheeler over the next couple of weeks. I am pretty sure that one is badged as a Columbia. I haven't seen it yet though. |
08-04-2014, 03:51 PM | #10 |
Not Yet Wild
Join Date: Jul 2014
Location: columbus ohio
Posts: 29
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Re: testing 3 way key switch on a harley cart
the three diodes i was referring to was like you said one at key two further down the line. sorry
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