91 Gas Starter / Generator or Voltage Regulator Problem

[DaddyBooks]

Hi All...

I am a to this forum and carts. I've spent quite a lot of time searching and reading. Thanks to all for the great information.

I recently purchased my first...a 1991 Club Car Gas cart. It ran fine when I tested it but I've discovered that after 2 weekends, the battery is dead. I can charge the battery and all is good for a while. 2 weekends later, dead again

After searching the forums, it appears that I have either a starter / generator problem or a voltage regulator problem. I am unclear as to the testing procedure for my pre-92 cart. I have the wiring diagram STICKY and a voltmeter and I'm not afraid to use them but am unclear of where to test, what voltages I'm seeking, etc.

One other item of note. In order to engage the starter, we have to hold the accelerator at only about 20%. If the accelerator is depressed more than that, the starter will not engage. We've gotten used to that but I wonder if it's related.

All help and guidance appreciated. Feel free to point me at an existing thread but I'm not able to locate one that fits my older cart.

Thanks for any and all advice to help me overcome my case of old cart "buyers remorse"...

...DaddyBooks

[jsahara24]

Originally Posted by DaddyBooks

Hi All...

I am a to this forum and carts. I've spent quite a lot of time searching and reading. Thanks to all for the great information.

I recently purchased my first...a 1991 Club Car Gas cart. It ran fine when I tested it but I've discovered that after 2 weekends, the battery is dead. I can charge the battery and all is good for a while. 2 weekends later, dead again

After searching the forums, it appears that I have either a starter / generator problem or a voltage regulator problem. I am unclear as to the testing procedure for my pre-92 cart. I have the wiring diagram STICKY and a voltmeter and I'm not afraid to use them but am unclear of where to test, what voltages I'm seeking, etc.

One other item of note. In order to engage the starter, we have to hold the accelerator at only about 20%. If the accelerator is depressed more than that, the starter will not engage. We've gotten used to that but I wonder if it's related.

All help and guidance appreciated. Feel free to point me at an existing thread but I'm not able to locate one that fits my older cart.

Thanks for any and all advice to help me overcome my case of old cart "buyers remorse"...

...DaddyBooks

I am not an expert but i am goign through similar problems with my 85 CC.

When the cart is running at half throttle and you check the voltage on your battery what happens? From your symptoms it sounds like it will be going down.

You can test your s/g by hooking your voltmeter up to the field terminal on teh s/g and reving it to half throttle and you should be getting 13-14.5 volts...

Also, you should take a look at the brushes in your s/g to make sure they dont' need to be replaced...

I am not sure how to test the voltage regulator, but i'll let you know once i figure it out! Good Luck, Jason

[Murphy]

1) Check for tight & clean connections. 2) Battery must be good and fully charged. 3) Run engine to bring up to operating temp. 4) Set VOM on DC-20 volt range. Measure across D+ and D- terminals of volt/reg. 5) At 2750-2850 RPM reading should be 14.5 to 15.5 volts. If lower than 14.5 but rising steadily check battery, If lower than 14.5 volts and not rising or over 15.5 adjust volt/reg. To adjust volt/reg, Loosen 7mm locknut on adjusting screw, Turning adjusting screw clockwise raises volts & counterclockwise lowers volts, this is also done @ 2750-2850 RPM, need 14.5 to 15.5 volts.

Good Luck

[mjrowley]

tag!

[MaxsCart]

I recently purchased a pre 1992 club car- ( im only saying this due to the seats)
Are the voltage regulators post-1992 compatible with the pre-1991 Voltage Regs?
Meaning may I upgrade to a non- adjustable voltage regulator?

[nickdalzell1]

Yes you can install a 'solid state' regulator in place of the old fashioned mechanical one. A voltage regulator is just a voltage regulator. It only does one job. You will have to do some minor wiring work (replacing the three small ring terminals with butt splices/insulated spade connectors) but that's it. Just take a photo of where they connect to the old one, but the colours are the same. Black = ground, red = solenoid output to starter generator, green/yellow = df terminal on starter generator.