YAMAHA G16 - 10 amp fuse keeps blowing

[Yamboy]

Hi Guys,

So after 3 years of storage outside under a tarp I decided that it’s time to get the thing going again. Cleaned it all down, came up looking good then moved on to seeing if I could start her. New battery in, key turned, nothing except the engine stop switch clicking. Voltage at the positive main terminal on the solenoid but nothing when the accelerator is pushed. Tried to jump across the solenoid and no response from the starter (automatically thinking that the solenoid is dead).

Anyhow I order a 12 volt solenoid (aftermarket one from ebay). Installed new solenoid, pedal down then nothing…. So, then I clean up all the connections I could see including the ground wires to the underside of the engine and the one attached to the solenoid bracket. I also took the starter off and removed the back end so I could check the brushes (3 of the 4 where stuck so I gave them a good spraying with contact cleaner and used some pliers to free them up. I then tested the starter with a 12volt battery and jump leads and it spun up to speed fine. Reinstalled starter to cart, ignition on, pedal pushed and now I’m getting a feeble 2 second spin of the starter followed by a “POP” of the fuse! Been through 6 x 10 amp fuses and it just keeps doing the same. I don’t know where to go from here? It was fine when I last used it. New brushes for the starter motor? is the aftermarket solenoid not man enough? Any help would be much appreciated as been spending a week on this thing ☹.

Many thank Steve

[1arunem]

Did you bench test the starter when you had it off?

[Yamboy]

Originally Posted by 1arunem

Did you bench test the starter when you had it off?

Yep, after I cleaned out the crud and freed the brushes I got a 12 volt battery and used jump leads to spin it up.