Clicking noise with no start

btstrnad

Hello to all,
I have a 2002 gas cart and am experiencing a clicking noise when pushing the pedal to start without the engine turning over. Lights work fine. Clicking is originating from under the electrical cover box. I have some mechanical experience and a limited number of tools available. Is there a simple fix for this, or should I find a repair shop.
Thanks.

BGW

__________________
This advertising will not be shown in this way to registered members.
Register your free account today and become a member on Buggies Gone Wild Golf Cart Forum

technician#2

Look at the top of the forum here and find the EZGO GAS TECH post. look at the post named "Need a Ezgo manual, diagram, or ID help?". go into that section and look at the manual for your buggy. find the electrical layout and schematic for your buggy.
If you have a trouble test light, check the solenoid under the black box by the battery, it is what you are hearing. you should have battery power on one side of the big terminals all the time, and on the other terminal when you step on the gas pedal and you hear the click. there is a small switch on the gas pedal which turns on and off the solenoid. If you have power on the solenoid, check the cable going to the starter/generator for power when you step on the gas pedal.
If you have power there, the starter brushes are maybe bad??
hope this helps.

sabercat

yep followe the power and check along the way for juice.

essness

btstrnad

btstrnad

Thanks for the advice and welcome. I have traced the problem to the starter. Figures it would be the most expensive piece. Can these be brought up to the auto parts stores to be tested and ordered, or will I need to order it online? The nearest cart shop is 90 miles away. Would appreciate any suggestions.

G keeling

Sounds like brushes in starter generator oare worn out. Gentle tap starter withhammer to see if it will start

G keeling

Sounds like brushes in starter generator oare worn out. Gentle tap starter withhammer to see if it will start

technician#2

I would take the starter/generator off and remove the back cover and take a look. This is a really simple device, and easy to work on with basic mechanical skills. It may be as simple as a stuck brush, or a broken spring. You should be able to get a set of brushes or whatever other parts you need from the auto parts store, and fix it your self. Look in the Tech section at the top of this forum, and look at this post: Need a Ezgo manual, diagram, or ID help?, then look at the first manual (pdf) ...this one: Technician's repair and service manual, and look at page 124. It has a break down of the starter/generator.

btstrnad

Hammer didn't work. Guess I will be removing it and taking a peek. Any special tips regarding this, or will it be just like the manual. Want to avoid the experience I had as a kid when I took my Dad's lawnmower apart and the spring from the pull starter almost took off my head!

technician#2

NAW... nothing like that, you just have to pre load the brush springs as you put it back together. No "snake in a can" surprises! Just take your time and look at it as you take it apart. If you want to you can make a mark on both pieces (end cap and starter body) prior to removing the end cap for alignment when putting it back together. Look at the brushes and see how long they are. If they are only a 1/4" or so long, they need replacement. I am not sure how long they are when new, but I am guessing around 7/8'' to 1". Also look at the commutator to see if it is burned, or has segments missing. There is definitely something amiss for the starter to not even try to turn. Look for a broken connection somewhere (as in a brush not making contact). That is where your current flow is stopped. And that is why it won't start. period.
Good luck... let us know what you find jb