Yamaha G2 Starter Issues

[timquagliata]

Here is the image.

https://drive.google.com/file/d/17zo...ew?usp=sharing

[CP241]

Where did you hook up the ground wire to?
How good is the frame ground for the cart too?

It’s hard to tell in your pictures, might be just grime, but the 2 sets of small wires at the top look somewhat melted too. You’ve definitely got something going on electrical

[timquagliata]

I agree, likely an electrical issue. Here are pictures of my ground to engine and ground to cart. Also, it was just grime on the 2 sets of small wires, they were not melted.

https://drive.google.com/file/d/1hAW...ew?usp=sharing

https://drive.google.com/file/d/1fI9...ew?usp=sharing

[CP241]

Here’s what I would do. Disconnect the battery and check continuity between the battery feeds and ground at the starter. Maybe it works but is shorted internally to ground and now that the engine has a ground, it’s getting hot and melty?

Unfortunately I don’t know how much help I can really be on this one without the cart in front of me. But I would say there’s definitely some sort of a ground issue in the cart causing it to arc from the engine to the dipstick like that.

With the sparks I saw I think it’s on the high voltage side (ignition coils output 20,000 volts or more) so maybe a problem with the coil as well? Just a guess, would be a lot easier with it in front of me.

[timquagliata]

Here is a little status update.

1. I removed the starter generator and took it apart and inspected the wires and the brushes. It looked like one of the brush connectors may have been shorted to the frame of the starter generator. I repositioned the connector away from the frame and put everything back together.

2. Once I got everything back together I tried to start it up and I get nothing at all. the solenoid isn't even clicking. (I'm guessing I fried something from my previous experiment)

3. I checked the fuses that I know about and they are all good.

4. I disconnected the small black and red wires from the solenoid and checked for continuity between the two solenoid coil posts and there was continuity (so good right?)

5. I disconnected the small red wire from the solenoid and connected my multimeter between the small red wire and the negative post of the battery. I turned the key to the on position and pressed down the gas pedal. With each press of the gas pedal I had battery voltage. So I assume that the on/off switch and the gas pedal switch are good, correct?

6. I disconnected the small black wire from the solenoid and connected the multimeter between the small black wire and the positive battery post and I did not have battery voltage. Is that something?

7. I also checked for continuity between a couple locations and this is what I got.
Small black solenoid wire and engine. Continuity
Small red solenoid wire and engine. Continuity

Do you have any thoughts on what I should try next?

[timquagliata]

I got it figured out. Initial problem was the solenoid. I replaced the solenoid and I also took apart the starter to see if I needed new brushes. Apparently when I put the starter back together, I had a brush wire shorting to the starter cover. Thinking I had a grounding issue, I added a ground wire from the battery negative to the engine. This caused a thermal event and after that I wasn't able to get anything (not even a click from the solenoid). So then began the wiring diagnostics. Eventually I figured out the starter brush issue and fixed that. While I was checking the wiring I found a fuse I previously didn't know existed... and it was blown. I replaced it and she back up and running. Thank you all for your help.