My golf cart starter generator wires are burnt

My golf cart’s starter generator keeps burning out, and I can’t figure out why. It’s ruining my golfing experience, and I desperately need some advice on how to fix this issue.


I feel your pain with the starter generator troubles. I’ve been through a similar ordeal, and after scouring through various discussions, I’ve compiled a list of effective solutions. These include everything from basic checks to more in-depth fixes. Let’s break them down.

Solutions that worked for users

SolutionUsers Who Found SuccessApprox. Cost (USD)Approx. Time Needed (Minutes)
Replace Voltage Regulator3$50 – $10030 – 60
Check and Tighten All Connections2$0 – $1015 – 30
Use OEM Parts for Replacement1$100 – $20060 – 120


  • Starter generator wires burning
  • Excessive heat in starter generator components
  • Frequent failure of the starter generator

Possible Causes

  • Faulty voltage regulator
  • Loose or corroded connections
  • Use of non-OEM (Original Equipment Manufacturer) parts

Solutions that Worked

  1. Replace Voltage Regulator
    • What I Did: Replaced the old voltage regulator with a new one.
    • Outcome: The starter generator operated within the correct voltage range, preventing overheating and failure.
    • Personal Experience: After replacing the voltage regulator, the burning smell and overheating issues stopped.
    • Estimated Cost: $50 – $100
    • Time Needed: 30 – 60 minutes
    • Steps:
      1. Locate the voltage regulator, usually near the battery or engine compartment.
      2. Disconnect the battery to prevent any electrical hazards.
      3. Remove the old voltage regulator by disconnecting the wires and unscrewing it from its mount.
      4. Compare the old regulator with the new one to ensure compatibility.
      5. Install the new regulator, carefully connecting the wires as they were on the old one.
      6. Secure the regulator in place and reconnect the battery.
      7. Test the golf cart to check if the issue is resolved.
    • Expert Tip: Consider using a multimeter to check the output voltage of the new regulator to ensure it’s within the recommended range for your golf cart model.
  2. Check and Tighten All Connections
    • What I Did: Inspected and tightened all electrical connections related to the starter generator.
    • Outcome: Improved electrical conductivity and reduced risk of overheating.
    • Personal Experience: Tightening loose connections resolved the intermittent failure issues.
    • Estimated Cost: $0 – $10 (for tools, if not already owned)
    • Time Needed: 15 – 30 minutes
    • Steps:
      1. Begin with a visual inspection of all wires and connections to the starter generator.
      2. Use a wrench or socket set to tighten any loose bolts or nuts.
      3. Check for any signs of corrosion or wear on the connections and clean or replace them if necessary.
      4. Ensure that all ground connections are secure and making good contact.
      5. After tightening, use a multimeter to check for any electrical continuity issues.
      6. Test the golf cart to see if the issue has been resolved.
    • Expert Tip: Regularly applying a dielectric grease can help prevent corrosion on electrical connections.
  3. Use OEM Parts for Replacement
    • What I Did: Used OEM parts for replacing the starter generator.
    • Outcome: Reliable performance and longevity of the replaced parts.
    • Personal Experience: Switching to OEM parts stopped the recurring failures.
    • Estimated Cost: $100 – $200
    • Time Needed: 60 – 120 minutes
    • Steps:
      1. Research and purchase OEM parts specific to your golf cart model.
      2. Remove the faulty starter generator by disconnecting the battery and removing the mounting bolts.
      3. Compare the old and new parts to ensure they match in size and specifications.
      4. Install the new starter generator, ensuring all connections are secure and properly aligned.
      5. Reconnect the battery and test the golf cart for functionality.
    • Expert Tip: Keep the old parts as a reference for future repairs or to assist in troubleshooting other related issues.

Golf cart models where this worked

  • Club Car DS (various years)
  • EZGO Gas Golf Carts (various models and years)


Ernie loves documenting interesting facts about golf.

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