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Old 10-31-2017, 09:24 PM   #1
JoshL
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Join Date: Mar 2016
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Default 87 Marathon 2 Cycle Generator Will Not Rotate. Voltages Listed In Thread

Good evening folks.

I have a 1987 Marathon 2 Cycle. I encountered a no start condition earlier this summer. Generator and engine would crank and crank but not fire. I let the cart sit since June as I bought a new Polaris Rzr.

Fast forward to today. I brought the cart home from our summer spot and hooked up a brand new battery that I know is in good working order. Generator would not move in either forward or reverse. I took the belt off and it appeared that it was stuck on the pulley behind the engine, possibly from sitting outside uncovered for several months. I put the belt back on and the generator would barely rotate. I worked the generator back and forth using the forward/reverse mechanism and it got better but would not rotate the engine more than 45 degrees. The generator seems weak and I almost think that my previous no start condition was from the generator not spinning the engine fast enough.

I checked the voltages at the battery, starter solenoid and the generator. Below is what I found.

Starter solenoid
IN 12.3 v
OUT 9.98 v (pedal depressed)

Starter solenoid
OUT 9.98 v
to
Generator F2 (followed battery cable to this lug) 9.62 v

Pedal depressed I found the following voltages at each lug:

F1 7.96 v (Reverse)
F1 8.06 v (Forward)

A1 0.00 v (Reverse)
A1 7.1 v (Forward)

A2 7.22 v (Reverse)
A2 0.00 v (Forward)

I have pulled the forward/reverse shift mechanism apart and cleaned. I checked ohms and continuity, all checked OK. I also checked all connections for loose or broken wires, all appeared OK.

Something tells me my issue is in the generator and not the starter solenoid or forward/reverse mechanism. Can anyone point me in the right direction?
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Old 10-31-2017, 09:27 PM   #2
Spicyunicorn
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Default Re: 87 Marathon 2 Cycle Generator Will Not Rotate. Voltages Listed In Thread

Pop the rubber caps off the end of starter generator and inspect the brushes minimum they should be above the holder
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Old 11-06-2017, 09:15 PM   #3
JoshL
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Default Re: 87 Marathon 2 Cycle Generator Will Not Rotate. Voltages Listed In Thread

I took the cap off the motor this evening, brushes look good and plenty of life left. The wire that goes from the screw hold down to the brushes are all intact.

I replaced the starter solenoid and that made no difference. Oh well, at least that is new.

I have a copy of the service manual and followed the steps to ohm out the forward/reverse/neutral switch. That checked out okay.

I am leaning to the generator/starter being old and worn out. Anyone know what I should try next before blindly ordering a new generator/starter?
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Old 11-07-2017, 07:46 AM   #4
Spicyunicorn
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Default Re: 87 Marathon 2 Cycle Generator Will Not Rotate. Voltages Listed In Thread

How far above the holder were the brushes
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Old 11-07-2017, 09:25 AM   #5
cart around
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Default Re: 87 Marathon 2 Cycle Generator Will Not Rotate. Voltages Listed In Thread

Remove the big wire from the output side of the solenoid. Check the output voltage on the solenoid lug while stepping on the pedal.

If you have that same low voltage as you did before, the problem is between the solenoid, and battery.

It could be corrosion crawling up the positive battery cable.
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Old 11-07-2017, 07:00 PM   #6
JoshL
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Default Re: 87 Marathon 2 Cycle Generator Will Not Rotate. Voltages Listed In Thread

Quote:
Originally Posted by Spicyunicorn View Post
How far above the holder were the brushes
Approximately 1/4" or so.

Quote:
Originally Posted by cart around View Post
Remove the big wire from the output side of the solenoid. Check the output voltage on the solenoid lug while stepping on the pedal.

If you have that same low voltage as you did before, the problem is between the solenoid, and battery.

It could be corrosion crawling up the positive battery cable.
Cables are not perfect but appear to be okay. I have ruled out cables at this point.

At the starter solenoid I have 12.3 volts. When you depress the pedal I have 9.2 volts. That is with the wires all hooked up. When I remove the wires from the starter solenoid on the output side and push the pedal I have 12.3 volts. I reattached the wires as it should be and checked volts again...9.2 volts. So I removed the big red wire from the F2 post on the starter/generator and checked volts at the starter solenoid again. With pedal depressed I have 12.3 going in and 12.3 volts going out. I have it narrowed down to the starter/generator as my voltages are all okay with the F2 post disconnected.

Starter/generator will be here on Thursday.
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Old 11-09-2017, 08:40 PM   #7
JoshL
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Default Re: 87 Marathon 2 Cycle Generator Will Not Rotate. Voltages Listed In Thread

New starter/generator came today. Has much more torque than the original one and seems to be operating much better.

I have a bigger problem though, engine is extremely hard to turn over by hand. I pulled the engine this evening. Will begin investigating.

I'm thinking because it sat for so long that the rings froze up. I'm gonna pull the jug later.
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