G29 10amp Fuse keeps popping upon pressing gas

[ChaoSki]

Trying to help out a friend with troubleshooting his golf cart. It's a 2008 Yamaha G29. His 10Amp fuse keeps popping upon pressing the gas pedal. I know these are the worse to troubleshoot.....

His other buddy changed the solenoid before we found that the fuse kept blowing. Solenoid is new.

So far I checked the following:
- All the wires that I can see (lot of them have plastic covers....). I didn't find any corrosion etc. Should We start ripping the plastic covers covers off?

- I found this post and tried it, but no luck
"Had a g29 with the same problem the other day. As soon as I put a new fuse in it, it would spark and blow. I unhooked avr/engine stop relay/solenoid small wires/starter generator charge leads and the forward reverse switch. I started by installing a fuse, no spark and didn't blow Hooked up the generator charge leads/ solenoid wires/avr and engine stop relay, no blown fuse Plugged in the f/r switch..POP. Not saying that is you culprit, but worth 5 minutes of your time to check it out. Good luck."

- I found few post saying Starter/Generator can cause this. What is the best way to test it without taking it off? I checked all the cables on it and they all looked fine.

- I was also thinking about checking Ignition Key Switch wiring and Pedal Sensor (but wasn't sure how to test that).

TIA

[cgtech]

If you dont have the original starter/generator on there, its probably a chinese aftermarket one that are known for doing this.

[ChaoSki]

Thanks for the reply. Starter is original.

[cgtech]

Ok, thinking, what's next.....
So, unplug the voltage regulator & try again. Think about getting one of these "automatic resetting circuit breakers" from the auto parts store, itll save the hassle of buying a box of fuses while your testing. I keep them in stock for tricky stuff. If it faults, itll turn back on in a few seconds so you can try again. Use it as a testing tool, if it trips "again & again" it wont be useful because after it warms up, its response is slower.

[ChaoSki]

Thanks, yep will try that next.I tried to get that from a local Autozone, but nobody around had it (10amp). We have few boxes of fuses. Im curious though, how does that breaker work? Usually, breakers have a switch on it to reset.

I think I already tried voltage regulator, but I did bunch of stuff at ones. Let me try it alone.

Up next, I think testing the starter? Just trying to figure out a best way to go about that.

[cgtech]

Check for any connection from the power terminals to the case of the starter. You would need to remove the cables to do the test. If any connections to case are found, that's bad.

[smallblock450sl]

I know I don't post much anymore, but I'll put in my 2 cents worth. cgtech is on point. disconnect the lead from the solenoid to the starter and try the pedal again, does the fuse "pop"? Did you try his test of disconnecting the voltage regulator?

[ChaoSki]

Thanks for replies!

Voltage regulator test done.

Starter/Generator - tested (works fine). We took the starter off and took off the cover to check the brushes, they look almost brand new!

Will take of the following next:
Check for any connection from the power terminals to the case of the starter. You would need to remove the cables to do the test. If any connections to case are found, that's bad.

disconnect the lead from the solenoid to the starter and try the pedal again, does the fuse "pop"?

Will keep you posted

[ChaoSki]

Alright, so all of the tests above are completed. Everything looks great. So far, almost every wire or anything I looked at looks in perfect shape (cart looks like it's new).

While I was inspecting the wires, I ran over the wires towards the back of the cart to the area over rear passenger wheel well. Noticed a big connector, so I unplugged it....and sure enough, fuse doesn't pop and the cart starts.

So of course I asked my friend to not drive it for time being as I'm not sure what the box is. Connector has at least 16-20 pins in it (guessing some kind of a controller? Computer?). I didn't have my jack and stands with me to take it out, as the only access to it is from rear pass wheelwell (which I will be removing next).

Any idea what that unit is?

Also noticed another small box with a connector in that area (some kind of a relay?).Didn't get a chance to disconnect that.

[ChaoSki]

Actually, I take that back. Looking at the pic, there is like 40 pins on this plug. Located above rear pass side wheel well. What is this unit?