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Old 10-06-2014, 07:57 PM   #1
BonzoHansen
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Default G16A keeps blowing the fuse

I'm working on a Yamaha golf cart for my son's little league. It's a 2001 model G16A. I suspect the starter/generator. But I do not want to start throwing parts at it.



It never stops running. it just wont start when the fuse pops so i don't know when it pops. lights & back up buzzer work with fuse blown. i cant say if it will run with a blown fuse but i suspect it does.

The cart does not idle, if it is running it is moving by design. So it makes it harder to troubleshoot but I managed a few things. Battery is relatively new and has 12.6v so I think the battery is fine. The starter/generator is putting out 15.5-15.9 when running, that seems too high to me for a 12v system. I suspect it needs a voltage regulator. If I raise the back wheels off the ground it starts every time and never blows the fuse. But on the ground I get one start out of it. Next time I try to go it pops. So that makes me think under load the starter failing.

I looked for bad connections, fixed one i did find but no help. there aren't that many connections.

s/g looks like this, i believe it is a Hitachi product.


Any advice what to look for/test?
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Old 10-06-2014, 08:17 PM   #2
essness
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Default Re: G16A keeps blowing the fuse

Would suspect that the lights are grounded to the frame. On a 16 that will blow the main 10amp fuse. You can put a 25amp fuse in to test this theory.
Some say you can run it that way and not worry about it but I personally would rather run all the grounds to the battery and replace the 10amp fuse.
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Old 10-06-2014, 08:22 PM   #3
BonzoHansen
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Default Re: G16A keeps blowing the fuse

Thanks. I've read about grounding issues when I was searching. I'm going to check that again as the lights appear to have been wired by monkeys. But they did run right to the battery IIRC. However that was done years ago and nothing has changed in a while, so I don't suspect that.
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Old 10-06-2014, 08:23 PM   #4
dbmachine
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Default Re: G16A keeps blowing the fuse

Put the cart on the ground and remove the drive belt. This should confirm your theory of the fuse not popping when the cart is not under load. This would be the same as with the cart in the air. cgtech will chime in soon. He is the guru cart mechanic on the forums and really knows his stuff with yamahas.
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Old 10-06-2014, 08:27 PM   #5
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Default Re: G16A keeps blowing the fuse

Btw the voltage while the cart is running around 15v is about right to ensure the battery stays good and charged between the continuous starting and stopping when putt putting around the golf course.
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Old 10-06-2014, 10:46 PM   #6
bigstik40
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Default Re: G16A keeps blowing the fuse

When you say it "never stops running" you need to clarify that. Running in my mind would indicate that the ignition is supplying spark and the throttle is open to some degree. I wonder if when you say "running", you mean the starter/generator is cranking the engine? Clarifying this will help us help you.

In lieu of pulling belt, you also could just put cart in neutral for testing.

If the cart never stops "cranking" , the solenoid high current contacts could be welded or the solenoid coil circuit may be energized by some alternate source (like a positive wire shorted to the solenoid positive wire).

If the cart never stops "running", the stop relay circuit could be bad. FYI, the stop relay ungrounds the blue wire when the relay is energized (grounding the blue wire kills spark). Keep in mind in order to keep running you would need spark and a little throttle opening. Normally when adjusted properly the throttle would be closed with pedal up so never stops running would be difficult to obtain.

Kind of a rambling post, but hope it helps - RAY
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Old 10-06-2014, 11:54 PM   #7
bigstik40
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Default Re: G16A keeps blowing the fuse

I reread your post and I think I now see what you are saying. I just want to offer a few more observations/suggestions:

1. Blown fuse would not allow cart to keep running so somehow your kill wire is remaining ungrounded with a blown fuse or fuse is not blown when you are running.

2. As mentioned previously fuse blowing is usually caused by connecting accessories between battery + and chassis. This causes excess current flow through the ground return fuse. Maybe try the 25 amp fuse as suggested and see what happens. Check further for bad/frayed/chafed wiring against the frame.

3. With key off, try checking for voltage across the blown fuse with a meter or maybe a test light. I think it should be very close to 0 v. A voltage reading or light glowing would indicate something connected between bat + and chassis.

Good luck - RAY
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Old 10-07-2014, 08:16 AM   #8
BonzoHansen
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Default Re: G16A keeps blowing the fuse

I didn’t realize it had a neutral. But some quick searching shows me if I put the selector in the middle that is in fact neutral. Huh, new fact for the day lol.

“Never stops running” – I mean it never dies while it is driving. It just doesn’t restart.

It pops 30amp fuses, so something is shorting somewhere. I cannot find any chafing wires anywhere.

I’ll try checking for voltage at the fuse with key off. I thought I did but I’ll do it again.

So 15.9v running is ok? That seems high to me. I’d expect 14.7 or so running, but not as high as 15.9.

Thanks, Scott-
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Old 10-07-2014, 08:31 AM   #9
essness
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Default Re: G16A keeps blowing the fuse

Scott, I've sent a msg to Smallblock, he should be along shortly..........
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Old 10-07-2014, 08:53 AM   #10
BonzoHansen
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Default Re: G16A keeps blowing the fuse

thanks!
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