Yamaha G19E 2001 Won't Go

[Steve B]

Brand new Li battery supplies 52V and new solenoid but nothing. The Tow/Run switch allows power to the big solenoid terminal when on Run and not when on Tow, so that seems to work, but nothing changes when any other switch is on or off (like ignition, reverse/forward) with the exception of the reverse buzzer which works intermittently. We think that is just a defective buzzer? When tow/run is sent to run, we seem to get power everywhere. Both sides of the control wires on the solenoid seem to be hot with 52V for some reason. Testing with the negative on the battery and the positive on either of the small terminals of the solenoid yields 52V. That can't be right? This must be a wiring issue? Where should the red/white control wire from the solenoid go? It seems like red/white is always hot? What voltage should red/white be? Any help would be appreciated. Thanks!

[Steve B]

Worked on it again today to no avail. Jumped the motor which operated so not that (although it did spark a little when we powered it up). Traced power past the dashboard switches to the throttle assembly, brown wire is hot coming off the accelerator switch. At this point we are confident that the tow/run, the main, the directional, the accelerator, and the potentiometer switches all work. Not sure about the solenoid which does not click but seems to work. We heard it click once but not sure how or why. The solenoid successfully sends power to the controller side high positive terminal on it when the tow/run switch is flipped to run and doesn't if it is flipped to tow. But the red wire with the black stripe connected to the controller from the solenoid does not seem to be doing its job. It always tests hot if tow/run flipped to run. All four of the wires on the solenoid test hot at full voltage when tow/run is flipped to run, regardless of what any other switch is set to. We are not sure if this is proper of not. We also have two controllers, albeit both old ones, that when switched out make no difference. So we don't think it is controller since same other conditions exist no matter which controller we are using. Looking for ideas. Thanks.

[Steve B]

Good news. We got the motor working today by using the controls on the cart. After we attached a controller box from another old Yamaha the solenoid started to click and the accelerator assembly made the wheels roll. It is working in test mode which means we have it all apart and we're manually operating the accelerator switches. Hopefully when we get it together again it will still work. We have a bit of a wining noise coming from the motor, if anyone knows what that is let me know.