G9 Starts by Jumping Solenoid, Then Nothing

[Terry1954]

Hi everyone. Old follower, but new to posting.

I have a G9 that fails to start when pressing the gas pedal. The oddity is this; I can jump the solenoid while pressing the pedal and it starts and runs.

I lower the seat and get 4 or 5 normal starts, then the cycle starts over.

I followed Smallblock’s post about using a meter to test and ended changing the solenoid even though I didn’t find any faults. (Had 12v every time and it started.)

Anyone seen this? What’s my next step?

Thanks in advance
Terry

[slonomo]

I know if you have worn out brushes in the starter/gen it can have trouble spinning. Once you get it spinning it will work for a little bit, then stop again. Not sure if that's it or not, but it's a common problem. If you have a factory starter/gen they are worth fixing. The aftermarket ones tend to have lots of issues.

[Terry1954]

Thanks Slonomo. I have another cart so I may be able to change out the starter/gen. This gives me a direction.

[Dave in VA]

New brushes, new bearings and a commutator cleanup, $78 at a local motor rebuilding shop...

[Terry1954]

Thanks Dave. We had rain all day today so didn’t even make it to the barn. Hope to check it tomorrow.

[Terry1954]

Ok, so had a little time to go over the cart again. Took off starter belt and it works and is strong. Took a test drive and it totally died. Not even a reverse buzzer.

Took a pic and I don’t think this should be happening when in reverse.

Also checked accelerator switch and it is good.

[Terry1954]

Ok, I’m back to square 1, maybe 2, after tracking wiring harness all afternoon.

I found some of the infamous “trailer splices” in the main harness and have been jumping wires to find my main issue. Still have at least one short or loose splice cause the back up buzzer stops when I wiggle the old harness.

Worse kick in the head was the solenoid. I had changed it last week while checking the issues and today put the original back on and was able to get the cart started. The square 2 is now it starts without the cheater wire from battery to switch that has been there whole time I’ve owned the cart.

Next weekend I’ll continue to work on the harness to make repairs and replace wires as needed.

Thanks
T

[Terry1954]

Ok, big update. My cart is actually a G2, not G9.

The good news is I’ve located my issue. It was a bad splice in main wiring harness, and possibly a bad ground cable. Either way, I’m getting closer.

It was strange that at some point the wiring harness had been dropped below the brake cables which left them exposed along bottom of cart center rail.

Now I have the harness back where it belongs and will be making corrections soon.

I enjoy this forum and the repair history it contains. That is how I found out I had a 2 instead of a 9.

Thanks
Terry

[Terry1954]

I didn’t list it, but the broken wire was the reverse buzzer wire. It appears there must be a full circuit to get 12v to the switch.

[Terry1954]

Ok, last entry.
Drove the cart yesterday & today. Starts as it should every time.

Here’s what I corrected:

Added new ground cable to starter.

Located and corrected a broken splice in main power wire going to switch. (This this had been bypassed since I bought the cart 5 years ago.) This seems to be an issue with lots of older carts. Some the wire was just rotten.

Changed to new Yamaha key switch.

Now to work on the Honda TRX350 for pulling to give this cart a break.

Cheers
T