04 Starter/Generator Burning Up
 

04 Club Car DS. My factory starter burnt the brushes up so I replaced them, then it really blew up and started smoking so bad that it damaged the armature. I bought a new starter and smoked it too. I did some research and it found that a bad voltage regulator can cause this. So I got the company to swap out the starter and I bought a new voltage regulator. Put the new parts in and all was well for about 10 minutes of riding and then it happened again. Starter was making a terrible noise and got really hot. I got it home and haven't looked at it yet due to frustration. Any ideas?

Thanks in advance!!!

Re: 04 Starter/Generator Burning Up
 

Did you buy OEM parts?

If not, buy real parts and problem solved

Re: 04 Starter/Generator Burning Up
 

I'm looking for the same answer.
Is the RPM limiter disconnected and are you driving long distances at high RPM?

And Golf cart guy, don't think that OEM real parts are going to fix his problem.

Re: 04 Starter/Generator Burning Up
 

I did not buy OEM parts. I disconnected the governor but the RPM limiter is still connected. Didn't want to blow it up. I basically drove around the block 2 or 3 times. Hit high speed once. I read somewhere that the generator wire could be grounding out. Looks like the wire is in good shape and still in the wire flex. But I am going to check it to be sure.

Thanks,

Re: 04 Starter/Generator Burning Up
 

Ive repaired hundreds of cars with this issue and never has anything like this. Its not rocket science, the Club Car gas cart is the easiest on the planet to fix, charging systems are even easier. And, as it turns out he didn't buy good parts. This isn't my first rodeo and its strange has anytime I see something like this, its due to aftermarket parts. The stuff has gotten worse in the last few years.

Re: 04 Starter/Generator Burning Up
 

His problem started with the "factory" starter. What do you think caused the starter to blow up and damage the armature after the brushes were replaced?

Re: 04 Starter/Generator Burning Up
 

Original issue was a voltage regulator charging at 17 plus volts, its a common failure. The bad regulator takes out the starter.

Had the cart been taken to a shop, they would have replaced the regulator and the starter, and that would have been it.

Re: 04 Starter/Generator Burning Up
 

So what exactly does a volt reg charging at 17 plus volts do to the starter?

Wouldn't it destroy the battery first? Boil out the water?

Re: 04 Starter/Generator Burning Up
 

Where is a good place to buy OEM parts?

Thanks,

Re: 04 Starter/Generator Burning Up
 

I get mine from David at Revolution Golf Carts. He is a site sponsor. Good prices, fast shipping, great customer service and knows everything about Club Cars.