94 EZ-GO gxt 804 will not crank

Col. Mustard

It doesn't even try to crank.

Very Brief History:

I bought this cart over a year ago, and sent it directly to a mechanic friend of mine for him to fix it up. He test drove it a few times, and said it would probably need to be rebuilt because it would not go up inclines at all. It moved slower than walking speed.

Then all of a sudden one day it kicked in and started going a lot faster than usual.

It's been at least a year now since it was cranked. I just finished adjusting the valves, changing the oil, spark plugs, air filter, fuel, cleaned fuel tank out, added fuel filter and changed fuel hose, uninstalled the one headlight it had, uninstalled the stereo, and charged the battery twice.

Every time I measure the battery with my multimeter the volts have gone down some. Is that normal? Should it crank if it's reading above 11 volts? For a little bit I was hearing the clicking sound that people have mentioned in the threads here coming from the solenoid. But after a few minutes it stopped doing that. Recharged the battery, and it still will not make the clicking sound.

I'm attaching a few pictures to see if I understand the info that I've been reading here at the BU forums correctly. Please let me know if I have something wrong. Is it supposed to crank as soon as you turn the key, or does it crank after you push the gas down (after turning the key)? Also, the spark plug wires come out of the plungers extremely easily (at the end without the plugs). Are you supposed to able to just pull them out with no force? There's also a wire coming from the below the valves next to the dipstick that looks to be from the factory. IT'S NOT connected to anything at all. Check the last picture to see what I'm talking about.

I've never actually witnessed my cart run with my own two eyes, so I'm pretty frustrated now. I would be very grateful for any help - I've already learned tons of stuff from this site

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

Quadmaster

You turn the key on, then when you press on the gas pedal it cranks...normally.
Have you tried starting it with jumper cables from a running 12 volt vehicle ??? Your battery could be bad, it sounds like you have low voltage all ready, the cranking power could be gone. A running vehicle with a working charging system will bypass your battery in effect. If it starts then buy a battery.

Col. Mustard

Thanks for the suggestion. I just tried jumping it, with no success. It still wouldn't even try to crank. No clicking.

Does all my wiring look correct? Is that indeed the solenoid in the picture I have labeled as such?

Quadmaster

Wiring looks good, That is the solenoid. Sounds like the solenoid is not doing it's job, but I'm not positive yet. ok just trying to think - is there 12 volts to the starter/ generator when your trying to start it??

pizzamaker

that white wire is for a elect oil gauge, take a screwdriver and go across the two large posts on the solenoid and see if it turns over, if it does then the solenoid is bad

Col. Mustard

I don't think the starter is getting any voltage, but I'm not exactly positive that I'm testing it correctly.

My Method of testing volts to the starter is putting the negative multimeter probe on the negative battery terminal. Then I put the red probe on the bolt that is pictured in the solenoid pic labeled "12v when pedal is pressed". I try to measure voltage on that bolt with the pedal pressed and get nothing. But the "12v constant" bolt in that picture has 11.44 volts.

ALSO, when I press the gas pedal the volts drop from 11.44 to Zero on the ignition switch terminals.

Col. Mustard

By "2 large posts" - are you referring to the 2 bolts that I have labeled in my solenoid picture? (12v constant and 12v when pedal is pressed)

Thanks for the info on the oil gauge wire and solenoid test!

pizzamaker

if you jump the solenoid you are byepassing the key switch and the pedal switch, is makes sure the starter is working! then go backwards from there.

Col. Mustard

Cool, I'll try jumping the solenoid. The 2 bolts right?

pizzamaker

yep, that the ones