Solenoid Issue

zielritter

Hi, All -
Newest issue with my '75 D popped up this morning while moving the cart from my garage to its new home under my rear deck. In reverse the cart runs perfectly. In forward gear the solenoid clicks and nothing - the starter motor doesn't spin or anything. Is this just a bad solenoid now that needs to be replaced?

Thanks,
-Matt

BGW

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tew45

It could be the starter. Check the output voltage at the solenoid and on the starter. Check the R/F switch.

raydhd

Also be sure all connections and grounds are clean.

zielritter

I don't think the solenoid is the issue as it runs in reverse and the voltage drop goes to zero between the + connection and the wire that runs to the switch when I press the gas pedal. The connections on the starter look OK too. My money is on the r/f switch.

If you look at the attached pictures one of the wires is cooked pretty good. I'm not 100% how or when this happened, but I can say that the symptoms I'm experiencing coincided with me having to add a new starter belt (the one on it broke last week). Maybe I tugged on the starter too hard when putting the new belt on and pulled the one wire into contact and fried something?

The only thing I see as odd is that this wire seems to be engaged in reverse as well. If it was shorting wouldn't it be affecting reverse as well? If you look at the diagram in the fourth picture the top wire that is burned seems to be engaged both directions. I'm kind of out of my depth here. I'm a noob at mechanical stuff and a total clueless idiot at electronics.

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IndianTraceDirtDauber

The wire that burned, call it 6 o'clock position, looks like it touched the nut of 1 o'clock position.

Trace down the path of 1 o'clock wire as that is a forward wire and see if there is any burn damage at it's length or end connection.

Sent from my SM-G930P using Tapatalk

zielritter

Starting running through the list of checks tonight. Beside the burned spot on the one wire pictured there doesn't appear to be physical damage to the other wires. Also, got the R/F switch removed. I cleaned it well and put some new nuts on it as the existing ones were really corroded. Check continuity per the manual's diagram and everything checked out.

I guess next is checking the output voltage at the solenoid, however, if it's firing in reverse wouldn't that rule out the solenoid? All it does it send current to the switch right?

The toasted wire... what does it do? It runs to a spot on the starter, but I'm not sure what it actually does. I might just replace it with some heavy wire (what gauge?).

Lochlin

You are correct in that if your solenoid is working fine for reverse than it is also working fine for forward. That cooked wire needs replaced. That wire will carry current from the switch to that starter. If too much of it is degraded it won't be able to carry enough current to spin the starter.

You should be able to switch the F and R wires on the switch. If your cart then goes into F but not R then you will know that there is something up with you wiring OR the switch itself.

zielritter

Ok, that makes sense. My stupid question, is which one is forward and which is reverse? The cooked wire looks engaged when the switch is in reverse or in forward. What am I missing?

From the wiring diagram it looks like the front wire (my cooked wire) goes to something marked A-1 on the starter. Back wire goes to A-2 and the remaining wire goes to something labeled F-2. Since looks like it's coiled into the solenoid is this my power? A-1 is forward and A-2 is reverse? Sorry, i'm nearly completely helpless when it comes to electrical.

Lochlin

Yep, A-1 and A-2 are F and R respectively. The Fs are ground. If you switch that A1 and A2 wires that will spin the start the opposite way as if you worked the switch.

The remaining wire on the starter / gen goes to the voltage regulator to charge the battery.

zielritter

That was it! Lifesaver once again. Appreciate it. I'll try not to break anything else between now and summer, but no guarantees.