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Old 04-19-2020, 07:45 AM   #1
AGELE55
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Default G1 third starter generator and still won't charge

I've read every post, sticky, article, comment, reply, opinion, and rumor.. still no joy.
Original S/G : Cart starts in FWD & REV and runs great, but will not charge the battery. Ordered a new S/G and got the same results. Returned it and got a new one from a different supplier. Same results.
Each S/G was tried with two different voltage regulators.
The only test each one fails is : 12v is at the VR and red S/G wire with key on. I remove the DF wire and ground it. Generator should produce charging voltage. It does not. Generator windings all read good with 5-6 ohms. The only oddity I see and cannot explain is this: If I meter the D- post to ground, it checks good at less than 1 ohm - UNTIL- I start the cart. The ohms to ground goes infinite/open. Yes, I physically chased /replaced the wire from end to end. I reworked the ground stud also. Same results.

I have spent 40 years troubleshooting electrical systems and I'm getting my but kicked.

I literally rang out every wire in this cart. I stripped off the harness wrapping and inspected for chafes.

You're all invited to my bonfire party when I burn this POS to the ground.
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Old 04-20-2020, 11:54 AM   #2
cgtech
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Default Re: G1 third starter generator and still won't charge

Aftermarket S/G are poo poo.
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Old 04-20-2020, 12:55 PM   #3
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Default Re: G1 third starter generator and still won't charge

You grounded the D/F wire, or grounded the D/F post on the starter?
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Old 04-21-2020, 06:45 AM   #4
AGELE55
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Default Re: G1 third starter generator and still won't charge

Quote:
Originally Posted by Golf cart guy View Post
You grounded the D/F wire, or grounded the D/F post on the starter?
Tried it both ways with no joy.
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Old 04-21-2020, 07:30 AM   #5
mikeasis
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Default Re: G1 third starter generator and still won't charge

the aftermarket starter generators are garbage, if you can find an OE one have it rebuilt. Ive heard the red and green wire on the aftermarket starter generators can be backwards, try flipping those and see if it charges
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Old 04-21-2020, 07:34 AM   #6
Lochlin
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Default Re: G1 third starter generator and still won't charge

I had a couple of carts do that. You are going to have to rewire your charging circuit as you probably have a wiring issue somewhere. Get your wiring diagram out and, starting at the starter/generator, start replacing wires until all of the wires are replaced.
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Old 12-13-2020, 09:57 AM   #7
AGELE55
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Default Re: G1 third starter generator and still won't charge

Update... I have no idea what fixed this, but now its working great. I suspect something to do with the ground circuit. I replaced the negative battery cable even though it checked out ok and noticed quite a few strands broken. I also cleaned all the bolts between the frame and the engine platform. Charging at 13+ volts.
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Old 12-13-2020, 10:05 AM   #8
slonomo
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Default Re: G1 third starter generator and still won't charge

Quote:
Originally Posted by AGELE55 View Post
Update... I have no idea what fixed this, but now its working great. I suspect something to do with the ground circuit. I replaced the negative battery cable even though it checked out ok and noticed quite a few strands broken. I also cleaned all the bolts between the frame and the engine platform. Charging at 13+ volts.
Never underestimate the damage corrosion and wear can do to battery cables. Nicely done, glad it's working for you!
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