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04-28-2020, 09:12 AM | #1 |
Not Yet Wild
Join Date: Aug 2018
Location: Mississippi
Posts: 19
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89 Marathon S/G melting DF wire
I have a 89 Marathon with a 3pg motor. Rebuilt it last year and about a month ago got it out for the season and it has run great, me and the fam have really enjoyed it. Just recently it left me stranded a couple miles from the house with my wife and 2 yr old. (we live in a lake community and golf carts are used to cruise around the lake and to amenities). We had to be towed home.
When I took a look the DF (small green) wire from the S/G was completely melted from the S/G all the way back to the voltage regulator. I replaced the wire. I then got on and searched the forum to see what could cause this. I was able to find how to check the charging circuit. I removed the drive belt and disconnected the DF from the voltage regulator and connected it to ground. With my multi-meter set to DC volts, I clipped my probes to the battery and got 12.3 V. I then started the cart. My meter immediately reset its self and would not give me a reading until I let off the gas and the motor stopped it would then read 13 V. From my research this test should have produced 17-18V. I then re-ran this test with the DF wire connected to the voltage regulator and got the same results. I should have expected to see 13.5-14V. I then replaced the voltage regulator with a new one and got the same results. This is very odd to me. My meter is rated for 600V and you wouldn't think that the S/G would be outside that range. So now I wanted to validate my meter was working correctly. I took it to my Jeep and clipped to the battery got 12V then started my Jeep and got 14.5V. This tells me my meter is working properly. This has me a little confused though. Either my ignition coil is feeding into my charging circuit or i am severely overcharging from the S/G. I have checked the wiring multiple times to the wiring diagram and i cannot find any problems. Everything seems to be connected properly. My guess is the S/G needs to be replaced but I just want a sanity check here before i spend the $$$ on one. Any shared experiences or suggestions or other tests to run would be greatly appreciated. |
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05-01-2020, 10:00 AM | #2 |
Not Yet Wild
Join Date: Aug 2018
Location: Mississippi
Posts: 19
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Re: 89 Marathon S/G melting DF wire
i'm guess this isn't a commonly seen problem.
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05-04-2020, 07:54 AM | #3 |
Not Yet Wild
Join Date: Aug 2018
Location: Mississippi
Posts: 19
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Re: 89 Marathon S/G melting DF wire
bump
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11-17-2020, 01:33 PM | #4 |
Not Yet Wild
Join Date: Aug 2018
Location: Mississippi
Posts: 19
|
Re: 89 Marathon S/G melting DF wire
Still haven't solved this anybody have any ideas?
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11-17-2020, 04:29 PM | #5 |
Test before replacing
Join Date: Aug 2013
Location: Ohio side of the Pennsylvania border.
Posts: 3,491
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Re: 89 Marathon S/G melting DF wire
It sounds like it might be struggling to find a good ground.
The negative battery cable should be connected to the frame. From there, you should have a large cable going to lug C which is located at the bottom of the FnR switch. From that same point on the frame, there should also be a large braided cable that attaches to the engine. Do you have that? |
11-17-2020, 04:42 PM | #6 | |
Not Yet Wild
Join Date: Aug 2018
Location: Mississippi
Posts: 19
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Re: 89 Marathon S/G melting DF wire
Quote:
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11-18-2020, 10:37 AM | #7 |
Not Yet Wild
Join Date: Aug 2018
Location: Mississippi
Posts: 19
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Re: 89 Marathon S/G melting DF wire
The grounds are present and properly hooked up.
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11-18-2020, 04:51 PM | #8 |
Test before replacing
Join Date: Aug 2013
Location: Ohio side of the Pennsylvania border.
Posts: 3,491
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Re: 89 Marathon S/G melting DF wire
Put it in forward. Hook your meter directly to F2 (positive), and A2 (negative). Let's see what happens there.
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11-20-2020, 08:00 AM | #9 |
Test before replacing
Join Date: Aug 2013
Location: Ohio side of the Pennsylvania border.
Posts: 3,491
|
Re: 89 Marathon S/G melting DF wire
I wonder if the df stud has rotated, and is shorting out on the inside of the inside of the starter.
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11-21-2020, 02:21 PM | #10 |
Not Yet Wild
Join Date: Aug 2018
Location: Mississippi
Posts: 19
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Re: 89 Marathon S/G melting DF wire
I still get the same thing at F2 and A2.
So disconnect the DF and see what it does? |
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