Club Car DS gas generator failure

[cruisinkruty]

If you are going to over rev it,you may want to change the pulley diameter a wee bit to slow it down,but do not go too large as it will have trouble starting

[Doc]

I've always wondered-how difficult is it to rebuild a stock starter/generator? Do they sell kits?

[TahoeDawgZ71]

Originally Posted by Doc

I've always wondered-how difficult is it to rebuild a stock starter/generator? Do they sell kits?

You can get basically any piece of the starter/generator you want. There is no "kit" put together by Club Car. I can send you an exploded diagram any time you want to figure out what parts you may need.

[Fairtax4me]

The most common thing that happens on the original starter/gen is the brushes wear out and the commutator wears.
Brushes are fairly easy to replace and only cost about $40 for the whole set.
The comm can be re-cut by an alternator/ electric motor rebuild shop if necessary. Most of the time just removing any scale or carbon with Emory cloth will suffice. The new brushes can be broken-in by spinning the armature shaft with a drill for a few minutes before re-installing on the cart.

[demo61x]

I have had two in a row where the commutator has come apart in pieces. still trying to figure out why, as I wait for the new generator to come.

[HBR]

Originally Posted by demo61x

I have had two in a row where the commutator has come apart in pieces. still trying to figure out why

Both where cheap ones from eBay?

[cruisinkruty]

At the course I work at When a starter/gen goes bad,it is usually the brushes the first time. If the brushes are worn past there limit I replace them...then when it fails again in about 2 seasons I replace the whole starter/gen. This has worked for me for over 10 years.

[Golf cart guy]

The statement that the commutator was worn out on the first starter, throws up the red flag. A over charging cart will cause the commutator to wear fast. Starters last a long time, 10-15 year old carts and the starter can still be rebuilt.
Aftermarket parts is part of the issue here, so get an OEM starter. The next step is like suggested, check the battery voltage while running. The system is not complicated.

[demo61x]

Wiring and the rest of the charging system are to spec, 14 to 15 volts. Is it possible this is trying to start and charge at the same time ? causing these armatures to fail ? What decides when it changes from start to charge ? micro switch ? or RPM. The rebuilder of the two failed units says the problem has to be on my end. PRETTY SURE ITS NOT !!! so they are not going to honor the 1year warranty. Cost me $30 to ship it back to them and they want to know if I want the old unit back. luckily for them they are in Georgia and I'm in Chicago or I would toss this through there window.... just want to cover all the bases before I install a O.E.M unit on it.

[Golf cart guy]

just put a oem one on it and be done. the system is not that complicated. very basic.

chalk it up as a learning experience.