1997 EZGO Workhorse 1200

Madman415 · 10-06-2012, 05:47 PM

Can't seem to figure out why my buggy is charging 17+ volts.

When it does it:
Above 2,000 rpm engine cold
When engine is warm, it jumps from 13 volts to 17 instantly

What I've done so far:
Replaced the green wire (Gen to Regulator)
Replaced Regulator 3x
Replaced Generator 2x
Replaced Solenoid 6x. (2x with a 12v until I realized it originally had a 14v)
Disconnected the green wire (gen to reg) ran the engine voltage goes to 12.8 volts regardless of RPM

Testing Results:
Green Wire from Gen to Regulator = 6.5 volts -/+ .5v [unplugged 12.8 volts]
At Battery = 17 volts
Fat Black wire Gen to Solenoid 17 volts
Red Wire Regulator 17 volts
Every wire in the electrical system is at 17 volts

Summary
Last week, gen green wire was putting out 13.6 volts
battery was getting 13.6 volts
entire electrical system was at 13.6 volts
The electrical system has been at 13.6 volts for the past 7 years

What else can I do to figure out why the voltage is so high
I'm open to any advice, this is the first time I've been stumped with this buggy so hopefully someone here is willing to help.

worqhors · 10-06-2012, 07:35 PM

Old batteries would show very high voltage if being charged. Experiment by using another battery.

Madman415 · 10-06-2012, 11:43 PM

Quote:

Originally Posted by worqhors

Old batteries would show very high voltage if being charged. Experiment by using another battery.

I hope it's not the battery, it's only a month old but either way,
I will still swap it out and see what happens.

Madman415 · 10-08-2012, 10:50 PM

bought the stock size BCI 24 for it, (had a BCI 65) no change. Put yet another new regulator on it, kept voltage at 14.6 for about a half hour and it's spiking again to 17 volts as soon as it's started. Any other suggestions?

RSP · 10-09-2012, 12:09 PM

Is the voltage regulator getting a good ground?

Madman415 · 10-11-2012, 07:37 PM

Quote:

Originally Posted by RSP

Is the voltage regulator getting a good ground?

I've been thinking that a bad ground is the demon all along. I just can't find a loose or crappy ground anywhere.

worqhors · 10-11-2012, 07:47 PM

You have to connect the battery to ground in addition to connecting the A1 of starter to the negative battery pole.

sonnyhooper · 10-12-2012, 07:48 AM

Take an Ohm meter and check resistance between ground post at the battery and the engine. A high resistance would show a bad ground. I have seen connections and wires that look ok and have found them to be bad.

Madman415 · 10-13-2012, 11:46 AM

Quote:

Originally Posted by worqhors

You have to connect the battery to ground in addition to connecting the A1 of starter to the negative battery pole.

I have the starter grounded with the factory braided line that splits off into two from the crimp connector. One goes to the frame and the other goes to the coil bracket. It's been like that for 7 years now.

If you're saying that there should be a wire from the starter ground directly to the battery (-) then I will try that too

Madman415 · 10-13-2012, 11:49 AM

Quote:

Originally Posted by sonnyhooper

Take an Ohm meter and check resistance between ground post at the battery and the engine. A high resistance would show a bad ground. I have seen connections and wires that look ok and have found them to be bad.

I have just found the books that came from EZGO in '97. I have the dealer service manuals. It still doesn't say what would be a "high resistance" battery to engine ground.

What would you consider a high resistance?

10-06-2012, 05:47 PM	#1
Madman415 Gone Wild Join Date: Nov 2009 Location: Pleasanton, Texas Posts: 267	1997 EZGO Workhorse 1200 Can't seem to figure out why my buggy is charging 17+ volts. When it does it: Above 2,000 rpm engine cold When engine is warm, it jumps from 13 volts to 17 instantly What I've done so far: Replaced the green wire (Gen to Regulator) Replaced Regulator 3x Replaced Generator 2x Replaced Solenoid 6x. (2x with a 12v until I realized it originally had a 14v) Disconnected the green wire (gen to reg) ran the engine voltage goes to 12.8 volts regardless of RPM Testing Results: Green Wire from Gen to Regulator = 6.5 volts -/+ .5v [unplugged 12.8 volts] At Battery = 17 volts Fat Black wire Gen to Solenoid 17 volts Red Wire Regulator 17 volts Every wire in the electrical system is at 17 volts Summary Last week, gen green wire was putting out 13.6 volts battery was getting 13.6 volts entire electrical system was at 13.6 volts The electrical system has been at 13.6 volts for the past 7 years What else can I do to figure out why the voltage is so high I'm open to any advice, this is the first time I've been stumped with this buggy so hopefully someone here is willing to help.

10-06-2012, 07:35 PM	#2
worqhors Gone Wild Join Date: May 2011 Location: Las Vegas NV Posts: 330	Re: 1997 EZGO Workhorse 1200 Old batteries would show very high voltage if being charged. Experiment by using another battery.

10-08-2012, 10:50 PM	#4
Madman415 Gone Wild Join Date: Nov 2009 Location: Pleasanton, Texas Posts: 267	Re: 1997 EZGO Workhorse 1200 bought the stock size BCI 24 for it, (had a BCI 65) no change. Put yet another new regulator on it, kept voltage at 14.6 for about a half hour and it's spiking again to 17 volts as soon as it's started. Any other suggestions?

10-09-2012, 12:09 PM	#5
RSP Gone Wild Join Date: Sep 2012 Location: Michigan Posts: 351	Re: 1997 EZGO Workhorse 1200 Is the voltage regulator getting a good ground?

10-11-2012, 07:47 PM	#7
worqhors Gone Wild Join Date: May 2011 Location: Las Vegas NV Posts: 330	Re: 1997 EZGO Workhorse 1200 You have to connect the battery to ground in addition to connecting the A1 of starter to the negative battery pole.

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10-12-2012, 07:48 AM	#8
sonnyhooper Getting Wild Join Date: Aug 2012 Location: minnesota Posts: 103	Re: 1997 EZGO Workhorse 1200 Take an Ohm meter and check resistance between ground post at the battery and the engine. A high resistance would show a bad ground. I have seen connections and wires that look ok and have found them to be bad.

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