Starter-Generator/ Electrical Mystery

CassT

'90 EZGO Robin 3PG motor. When stepping on acc to start I was increasingly getting just a hum from the Strtr/Gen & a 1/2 turn or so of rotation. Usually if I waited a few secs or kept pressing/releasing the acc it would kick over normally and run. I finally decided the Strtr-Gen which was the original Hitachi was going bad or need brushes so I just bought a new one. After install it does the exact same thing. After tracing voltage all through the micro-switches, cleaning all the cable terminals, confirming the solenoid was working etc I put 12v through a jumper cable directly to F2 on the Strtr which is where the solenoid cable goes. Exact same thing- hum and barely a 1/2 turn of the engine. I can easily turn the eng. by hand with the centrifugal clutch so it's not seized. I'm stumped- any suggestions on how else to troubleshoot would be appreciated.

BGW

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cart around

Load test your battery.

Put a meter on the battery terminals. Full charge is 12.74 volts. Now step on the pedal. The usual drop is 1 volt. If the voltage drops to 9.6 volts, or less, the battery is junk.

CassT

Battery is new and fully charged.

cart around

Ok, since you have bypassed the positive battery cable, we know it's not that.

I would take the FnR switch apart, and clean all of the large copper terminals.

This is your wiring diagram. http://www.buggiesgonewild.com/attac...n-retrofit.jpg

CassT

Thanks- I sanded and cleaned every cable terminal again, cleaned or replaced every wire connection, took apart & cleaned the F-N-R module. Not sure where the resistance was but now it works perfectly.