G16E goes then doesn't

thatlarryguy · 07-29-2018, 10:07 AM

My G16E quit a couple of weeks ago and has been driving me insane since.I replaced the solenoid since that was the problem 4 years ago and all seemed well. It worked for a week and started this intermittent stuff. There appears to be a connection somewhere that is not constant. The batteries are 4 years old, but I have 38+ on the pack and each battery tests around 6.5 volts. I pulled the motor and replaced the brushes even though the old ones didn't look that bad. Tested the motor with a 12V battery charger and it worked. Next, I replaced the battery cables.

After replacing the cables, the cart runs. When I replaced the curtain between the batteries and the electrical components, the cart quit again. No click, no nothing. If I wiggle the small wires (or rock the cart from side to side) it will work until whatever connection loses contact again.

Not sure where to go next.

cgtech · 07-29-2018, 11:06 AM

I'm betting F&R.

LPnTX · 07-29-2018, 11:10 AM

Bingo! Same thing happened to my old G16. QUOTE=cgtech;1526048]I'm betting F&R.[/QUOTE]

thatlarryguy · 07-29-2018, 11:25 AM

Thanks for the starting point. I just printed off the wiring diagram and the troubleshooting pages from the service manual and heading out to start testing. I'll report back.

thatlarryguy · 07-29-2018, 12:54 PM

F&R tests good according to the service manual. Has continuity on yellow wires either position. Open in neutral.

Of course the cart is working fine with the back end off the ground

thatlarryguy · 07-29-2018, 01:21 PM

Decided to let it down and go for a ride. Didn't make it. After replacing the seat, it is dead again. I tested the accelerator speed switch and it appears good. I had tested the stop switch before and it tested good.

thatlarryguy · 07-29-2018, 01:52 PM

I think I found it. Pulled the key switch out and one of the connectors had corroded in two. I guess tugging the wiring harness was initiating contact for a little while.

Thanks for all the help, I guess I'm going shopping for parts.

07-29-2018, 10:07 AM	#1
thatlarryguy Not Yet Wild Join Date: Jul 2018 Location: Burnet, TX Posts: 6	G16E goes then doesn't My G16E quit a couple of weeks ago and has been driving me insane since.I replaced the solenoid since that was the problem 4 years ago and all seemed well. It worked for a week and started this intermittent stuff. There appears to be a connection somewhere that is not constant. The batteries are 4 years old, but I have 38+ on the pack and each battery tests around 6.5 volts. I pulled the motor and replaced the brushes even though the old ones didn't look that bad. Tested the motor with a 12V battery charger and it worked. Next, I replaced the battery cables. After replacing the cables, the cart runs. When I replaced the curtain between the batteries and the electrical components, the cart quit again. No click, no nothing. If I wiggle the small wires (or rock the cart from side to side) it will work until whatever connection loses contact again. Not sure where to go next.

07-29-2018, 11:06 AM	#2
cgtech Over This Interview Is... Join Date: Jun 2012 Location: AZ Posts: 17,449	Re: G16E goes then doesn't I'm betting F&R.

07-29-2018, 11:10 AM	#3
LPnTX Gone Wild Join Date: Oct 2014 Posts: 173	Re: G16E goes then doesn't Bingo! Same thing happened to my old G16. QUOTE=cgtech;1526048]I'm betting F&R.[/QUOTE]
LPnTX Gone Wild Join Date: Oct 2014 Posts: 173

07-29-2018, 11:25 AM	#4
thatlarryguy Not Yet Wild Join Date: Jul 2018 Location: Burnet, TX Posts: 6	Re: G16E goes then doesn't Thanks for the starting point. I just printed off the wiring diagram and the troubleshooting pages from the service manual and heading out to start testing. I'll report back.

07-29-2018, 12:54 PM	#5
thatlarryguy Not Yet Wild Join Date: Jul 2018 Location: Burnet, TX Posts: 6	Re: G16E goes then doesn't F&R tests good according to the service manual. Has continuity on yellow wires either position. Open in neutral. Of course the cart is working fine with the back end off the ground

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07-29-2018, 01:21 PM	#6
thatlarryguy Not Yet Wild Join Date: Jul 2018 Location: Burnet, TX Posts: 6	Re: G16E goes then doesn't Decided to let it down and go for a ride. Didn't make it. After replacing the seat, it is dead again. I tested the accelerator speed switch and it appears good. I had tested the stop switch before and it tested good.

07-29-2018, 01:52 PM	#7
thatlarryguy Not Yet Wild Join Date: Jul 2018 Location: Burnet, TX Posts: 6	Re: G16E goes then doesn't I think I found it. Pulled the key switch out and one of the connectors had corroded in two. I guess tugging the wiring harness was initiating contact for a little while. Thanks for all the help, I guess I'm going shopping for parts.

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