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Electric Yamaha Electric Yamaha Golf Cars; G1 through "The Drive" and U-Max Utility Vehicles



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Old 10-25-2017, 02:53 PM   #1
Jamesotn
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Unhappy G22E Nightmare !!

2004 Yamaha G-22e. Bought with dead batteries. Put a new set in...ran about 75ft and quit. A tech checked all the wiring and where the harness has 20 or so of those pin plugs that go into the controller, some were loose fitting. However he checked all the switches on the accelerator, potentiometer, ign sw, and f/r sw, and tow run and all were good. When I stepped on the accellerator it ran very good forward and reverse. He said I should order a new harness which I did ( $200). I installed the harness one connection at a time..removing the old...installing the new. Would not run. I sent the controller off for rebuild and it was fine.
Today just for heck I installed a new solenoid. Battery pack voltage 51.1
tow run sw 51.1 ign sw 51.1 incoming on solenoid 51.1 outgoing on solenoid to controller 49.1
On the controller with my meter to the common ground A-1 = 49.1
A-2 = 49.1
No solenoid click when turning on ign
No solenoid click when activating tow/ run sw
No click w/ pushing down on accellerator
Yes I have it on jacks and rotated the wheels I'M LOST !!!!!
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Old 10-25-2017, 03:30 PM   #2
trentofdestiny
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Default Re: G22E Nightmare !!

I just had a nightmare with mine too. Had a bad solenoid but jumping the big posts on the solenoid didn't make it work. I know you said you have a new solenoid but disconnect the plug and measure the ohms at the small terminals. Also make sure you put the small wires on correctly.

All the voltages you listed are normal. For some reason, the battery voltage comes in through the little wire in the plug, through the controller and reads live on A1, A2, and the + term from solenoid.


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Old 10-25-2017, 05:29 PM   #3
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Default Re: G22E Nightmare !!

what should the ohms be at the small terminals ???
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Old 10-25-2017, 05:30 PM   #4
trentofdestiny
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Default Re: G22E Nightmare !!

It should NOT be close to zero or read "OL" which is open. I think mine was around 200-400 ohms. And you can't measure it with it plugged into the cart's harness


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Old 10-25-2017, 05:53 PM   #5
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Default Re: G22E Nightmare !!

o.k. I'll give it a try
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Old 10-25-2017, 05:54 PM   #6
trentofdestiny
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Default Re: G22E Nightmare !!

That's how I found out my solenoid was bad. BUT, the controller was "smart" somehow and kept from running the motor even if I jumped the solenoid


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Old 10-25-2017, 06:53 PM   #7
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Default Re: G22E Nightmare !!

Quote:
Originally Posted by trentofdestiny View Post
That's how I found out my solenoid was bad. BUT, the controller was "smart" somehow and kept from running the motor even if I jumped the solenoid


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Yes, the controller knows when the solenoid is behaving abnormally.
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Old 10-25-2017, 07:37 PM   #8
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Default Re: G22E Nightmare !!

O.K. But the solenoid is brand new out of the box. So cg tech will it make any difference if the two wires at the bottom of the solenoid are switched ? The one time it did run, I could swear that the wires were on the same terminals they are now. Surely it's not possible that the $200 harness isn't wired right ??
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Old 10-25-2017, 07:42 PM   #9
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Default Re: G22E Nightmare !!

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Originally Posted by cgtech View Post
Yes, the controller knows when the solenoid is behaving abnormally.

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Old 10-25-2017, 08:02 PM   #10
trentofdestiny
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Default Re: G22E Nightmare !!

Quote:
Originally Posted by Jamesotn View Post
O.K. But the solenoid is brand new out of the box. So cg tech will it make any difference if the two wires at the bottom of the solenoid are switched ? The one time it did run, I could swear that the wires were on the same terminals they are now. Surely it's not possible that the $200 harness isn't wired right ??


For the small terminals, the red should be on the small terminal closest to the mounting bracket on the solenoid. Black on the other terminal.


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