96 Club Car Gas will not Crank

[Franco832]

Good Evening Everyone,
I recently purchased a 96 club car ds gas as a project. (Cart is in really bad shape). The wires were all chewed up, so I went ahead and replaced them all with new. I followed the serviced manual specs. The cart will still not crank unless I jump the solenoid (solenoid is brand new). Can anyone help point me in the direction? Does anyone have a picture of the key switch wiring arrangement? Any pictures would be a huge help. Thank you!

[meimk]

With the key on, do you have battery (+) voltage at the blue wire going to one of the small terminals of the solenoid?

[Franco832]

Thank you for your reply. So the blue wire should have at least 12 volts at the solenoid?

[lockman1]

Originally Posted by Franco832

...Does anyone have a picture of the key switch wiring arrangement?

pedalstartkeyswitch.jpg

[Franco832]

Huge Thanks Lockman!!!

[Fairtax4me]

Originally Posted by Franco832

Thank you for your reply. So the blue wire should have at least 12 volts at the solenoid?

Yes. Blue is power from the Key switch.
Orange is negative through the throttle microswitch and the shifter switch at the FnR.
With the Key On, you should measure 12V at both small terminals. When you put the FnR in F or R and press the Go pedal, the Orange wire should drop to 0V.

For testing you can put the cart in "maintenance mode". There's a yellow plastic cam on the back of the FnR lever. Pull the cam out and rotate it 180° and let it pop back in and then you can start the engine and run it with the shifter in Neutral. It's always a good idea to have the rear wheels off the ground for testing as well, just in case.

[Franco832]

The voltage all checks out. Still nothing. Does the voltage regulator/ and or solenoid need to be grounded? I have to be missing something stupid. lol.


The only wire I have disconnected is the oil sensor coming off of the engine. The cart does not have an oil temp sensor currently. Should this be connected to something to close the circuit?

[meimk]

Did you check the Blue (+) and orange (-) at the solenoid small posts as Fairtax4me mentioned? Key on, either in gear or in neutral in "maintenance" mode, pedal down. If you have + on that blue wire and ground on the orange wire the solenoid should be engaging. Completing that control circuit is what works the solenoid. If all that IS correct and it still does not switch on the solenoid, then the solenoid is bad.

[Franco832]

Thank you guys for all of your help. I finally figured it out. The cart transmission was in neutral the entire time. I popped it into forward and depressed the gas pedal and she cranked. Now no spark......the investigation continues.

[CP241]

Try this link ---> http://www.buggiesgonewild.com/gas-c...-no-spark.html


1996 may still have a separate igniter behind the rev limiter, just something to keep in mind. Newer ones the igniter is built into the coil, but most of the same troubleshooting will still narrow down to either igniter/coil regardless.

Also, on the back of the shifter is a yellow knob. Pull it out and turn it 180 degrees until it clicks back in. This will let it run in neutral for troubleshooting. Make sure to pull it out and spin it back once you get it going or it won't run in F or R. And always a good idea to put the back axle on jack stands just in case