2012 club car fuse blowing

[Henrymacomber]

Which wire is considered to be the "hot" wire going to the start/gen? Yellow?

[Henrymacomber]

Is the yellow wire going to the start/gen the "hot" wire?

[lockman1]

The large white wire is the hot for the S/G.
The yellow wire tells the generator what voltage to put out while the engine is running.

This diagram may be easier to understand than the CC schematic.

[lockman1]

And another...
Even though the fuse started to blow before you replaced the key switch, no harm in double checking the wiring of it.

[Henrymacomber]

There's definitely something weird going on, I have my test light connected to ground, and when I touched the small post on the solenoid with orange wire attached the starter engages??

[Fairtax4me]

That's because Orange on the solenoid is the negative side. Power comes in on the Blue wire from Key switch. The Orange is grounded by the Throttle switch and the limit switch on the FnR lever.
By connecting your test light there, you provide ground for the orange wire, when the Blue wire has power (key On) the solenoid will close in and send power to the S/G.

[Henrymacomber]

I figured that out by looking at one of my other ones, but thank you for confirming it. Everyone who posted replies, I appreciate the help, I still haven't found the problem yet. I keep feeling like it's something simple right in front of me but can't see it. I'm considering putting in a new wiring harness.

[Fairtax4me]

Does the cart have any accessories or lights that only work when the key is on?

You should really only have to wires coming from the key switch that could cause this problem. The Blue wire to the solenoid, and the Yellow wire to the Oil warning light in the dash.
Unless something else has been added, those are the only two things that get power immediately when the Key is turned On. Depending on how the ignition switch is oriented in the dash, either of those wires could be rubbing against the dash frame.

As I said before, try removing the fuse, and use some wire connectors to connect a small light bulb across the terminals of the fuse holder. The light bulb provides resistance in the circuit, and is a visual indicator that goes Out when you find the short. It will not continuously burn out and waste multiple fuses trying to find the issue.

If you have any accessories or lights that may be tapped off of the Key switch wires, try removing those First, One at a Time, to narrow down possibilities and help focus where you need to look for the problem.
I promise you it's not difficult, although it may be a bit time consuming, this is only a golf cart, and there are only maybe 4-5 possible circuits at the most where a short can occur that will blow that fuse when the key is turned on.
Isolating which circuit that is, is just a matter of disconnecting each one until you find the one that makes the light bulb go out.
Disconnect accessories first, anything that has been added on like lights, stereo, horn, etc.
Once those are disconnected, if you still have the light On when the key is turned On, then there are only a few wires left and those are the Blue to the solenoid, or the Yellow to the oil light. Both are easy to unhook from the switch to narrow down which circuit the problem is in.
There could be other wires there that I don't know since I can't see the cart, but follow the same process with disconnecting one wire at a time from the key switch, and you'll be able to rule those out.

The key switch does have a ground contact, which controls the ignition kill circuit, so there are several wires that are Ground wires on the back of the switch. If your key switch has been replaced at some point with a Non-Club car switch, then this may not apply.

[Henrymacomber]

Originally Posted by Fairtax4me

Does the cart have any accessories or lights that only work when the key is on?

You should really only have to wires coming from the key switch that could cause this problem. The Blue wire to the solenoid, and the Yellow wire to the Oil warning light in the dash.
Unless something else has been added, those are the only two things that get power immediately when the Key is turned On. Depending on how the ignition switch is oriented in the dash, either of those wires could be rubbing against the dash frame.

As I said before, try removing the fuse, and use some wire connectors to connect a small light bulb across the terminals of the fuse holder. The light bulb provides resistance in the circuit, and is a visual indicator that goes Out when you find the short. It will not continuously burn out and waste multiple fuses trying to find the issue.

If you have any accessories or lights that may be tapped off of the Key switch wires, try removing those First, One at a Time, to narrow down possibilities and help focus where you need to look for the problem.
I promise you it's not difficult, although it may be a bit time consuming, this is only a golf cart, and there are only maybe 4-5 possible circuits at the most where a short can occur that will blow that fuse when the key is turned on.
Isolating which circuit that is, is just a matter of disconnecting each one until you find the one that makes the light bulb go out.
Disconnect accessories first, anything that has been added on like lights, stereo, horn, etc.
Once those are disconnected, if you still have the light On when the key is turned On, then there are only a few wires left and those are the Blue to the solenoid, or the Yellow to the oil light. Both are easy to unhook from the switch to narrow down which circuit the problem is in.
There could be other wires there that I don't know since I can't see the cart, but follow the same process with disconnecting one wire at a time from the key switch, and you'll be able to rule those out.

The key switch does have a ground contact, which controls the ignition kill circuit, so there are several wires that are Ground wires on the back of the switch. If your key switch has been replaced at some point with a Non-Club car switch, then this may not apply.

There are no accessories on this cart, it's stock, with no modifications. Also, I have the key switch hanging out of the dash, so it's not rubbing anywhere.

Just so I have this clear in my head, key switch on, bulb in place of the fuse, the bulb should be lit? Sorry if my questions sound dumb I just want to understand so I can proceed properly

[Henrymacomber]

The blue and yellow wires were connected to the switch with 1 terminal, I separated them. With the blue wire completely disconnected it has no continuity to ground, so this wire isn't the problem correct?