Yamaha G9 Charging and Starting problem!!!!

ToManyToys

First off...hello everyone. I'm new here to this forum stuff. I have a problem here that has really stumped me bad. I have a 1994 Yamaha G9, gas cart I purchased to use around the campground. When i got it it would not start via the gas pedal switch. The previous owner had just installed a momentary push button switch that would crank the engine, and if you gave it a little gas the engine would start and off you went. I wanted to fix it right and have it work as originally designed. I eliminated the push button switch, fixed some bad terminals on the starter solenoid, replaced a chaffed wire.

I had got it so it would start via the gas pedal but then the engine would continuously run and not shut off when you release the pedal. I did some googleing and saw many cases where people said that a bad voltage regulator would cause this. So i disconnected the regulator and all of the sudden the cart would start,run,shut off like it should, but i'm sure it wasn't charging. So i bought a regulator from a cart guy on ebay, once i got the regulator i installed it. Now, The first few times i pressed the gas pedal it would snap the 10 amp fuse, then the regulator just started making sizzling noises and i think it burnt up internally. Now the engine wont even crank with this new regulator plugged in. If i unplug it, cart runs good.

I got a G9 schematic from the internet and did some poking around. I found that there is a small tan wire from the regulator that shares the same big terminal on the starter solenoid as the big red wire between the solenoid and starter motor (the one i'm holding in the pic). I noticed that when i disconnect this tan wire at the solenoid, i can start start and run the cart but of coarse it doesn't charge. I feel like i'm forgetting a few details, but right now my brain is fried from starring at this thing for three nights!!! I really appreciate any help you guys can give me!! Thanks

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ironmonkey17

I'm in the same boat as you, and this guy (nonobaddog), when I have the tan wire disconnected everything works as it should except I have high charging amps, I tore my harness out today and checked everything, it has to be VR, check out his post..
http://www.buggiesgonewild.com/gas-y...tive-fuse.html