installed new starter brushes on my G9

[davekayse62]

* brushes... the starter randomly stopped working one day, so my battery tested good and I checked for voltage and voltage drop at the starter and it has plenty of power and the ground check out good also.

I removed the brushes and they were worn all the way down to what it looks like to be a wear line? so I ordered new ones from buggies unlimited.

but the new ones were not rounded on the ends that make contact like the old ones were, they were flat. I installed them anyways

now the cart will struggle to turn over for a bit then it will randomly turn normally. it can take up to 30 seconds. very annoying.

do I simply have to drive the cart a lot to break in the brushes or it my starter simply toast.

[Mike Mac]

Dave, you need to get brushes from a vender on this site. That other place is like home depot, "cheapest thing money can buy". It's always best to use quality parts.

They should have been concave, so not to ark on the commutator.

Just thinking, you may want to check yours, don't want them arking on the commutator, they will burn it up!

Pictures of mine are on page 943 in the G8 Club!

[davekayse62]

i was thinking that when I installed them too, bummer. may I ask you where you purchased your brushes from?

[Mike Mac]

I got mine from smallblock450sl, but CPP or any of the other venders on here will have quality parts for Yamaha's!

Smallblock is on this side of the country, all the venders are on the east side.

[bigstik40]

The commutator on the armature of your starter may need to be turned and have the mica undercut. An automotive starter rebuilder should be able to do this for you. What happens on these starters is the copper of the commutator wears more than the mica insulation between the bars. This condition does not allow the brush to make good contact with the copper bars. The rebuilder will turn the copper commutator on a lathe, then will "undercut" the mica insulation separators below the copper bars using special rotary saw blades. I have not personally seen replacement brushes for our golf car starters but have seen many replacement brush sets for similar auto generators and starters and new brushes usually are flat on the ends. The curvature wears in pretty quickly with use. Hope this helps - Good luck. - RAY

[Mike Mac]

Stick, I'm pretty sure mine, (from block) were concave when I got them.

[bigstik40]

I was just saying the ones I am familiar with have square ends (not concave). I just took a quick look at the offerings on E-bay and quite a few there were square (even some claimed Yamaha's looked square). Could not see any that were concave, but then some pics. were bad. I think a cleanup on his commutator would solve his problem. - RAY