1982 Yamaha G1 not charging

[kantuckian]

Good Info

[ratrodin]

??/????

[slonomo]

Are all of your connections super clean? Corrosion, dirt, rust, anything but shiny metal can cause resistance and poor contact.

Are all of your cables in good condition? Low voltage cables can corrode all the way through where you can't see. You can take a utility knife and remove a little insulation here and there to check. If it's green, powdery, or discolored, it has too much corrosion and needs to be replaced. Old golf carts, old cables. Replace all the wires/cables one at a time.

If you are using a new starter/gen, have it bench tested to see what it's output should be. Some auto parts stores can do this for you. Take the wiring diagram with you. If the parts store has someone knowledgeable they can do it. If they tell you "We can't test those" then it means they don't have the knowledge.

[slonomo]

Also, invest in a service manual. They have tons of info that might help you out. We'll do our best to guide you in the right direction, but ultimately it's your mechanical ability that needs to get it fixed. We'll try our best.

[Lochlin]

Personally, at this point I would replace every wire in your charging circuit. This would be every wire coming out of the VR and the small wires coming out of the generator. The generator ones are likely the same but there are multiple ways to wire the VR and have things work. Make sure that the primary cart ground (- on the battery to the cart itself) is clean and in good shape. I would probably replace it as well. Understand that wires can degrade inside the insulation. They may look good on the outside but inside there are issues.