How to Remove, Wire & Test a Golf Cart Starter Generator


golf cart starter generator

 

Safety Disclaimer: Don’t attempt to perform any of the steps on this page unless you’re a trained technician/mechanic. 

How Do You Remove a Golf Cart Starter Generator? 

Before anything else, you should take some photos of the starter generator and its wiring as possible. Taking photos will definitely help you remember where all parts were originally located.

Take note of how everything is wired and positioned, then label the wiring of the starter generator. 

After doing all that, to remove your golf cart starter generator: 

1) Disconnect the negative battery cable. 

2) Loosen and then remove the top and bottom bolts of your starter generator.

3) Remove the belt of your starter generator and leave it around the engine.

4) Loosen all of the wiring and remove them each by hand. 

5) Take note of which wire goes where. If you’re not sure you can remember which wire is which, you may label each of the wires.

6) Install the new unit with the old hardware then slip the belt around it. 

7) Adjust the tension of the belt using the top adjuster bolt.

8) Tighten the top and bottom mounting bolts.

9) Reconnect all the wires and make sure they’re not overtightened. 

10) Make the battery cable and the battery touch lightly. Check and make sure that there’s no big spark because this would mean something’s connected wrongly, something’s touching ground or there’s a short.

11) If the test goes well, reconnect everything.

12) Jack up the back of your cart, leave the body up, put in and turn the key then press the gas pedal as a final test.

 

How To Replace Golf Cart Starter Generator Brushes

Bad brushes should be changed to ensure your starter generator works properly. Bad brushes tend to cause your starter to malfunction first, then as it gets worse, it affects your generator.

To replace the brushes of your golf cart starter generator, you must: 

1) Unscrew the screws near the end of the case.

2) Pull the end of the starter out of the case.

3) Check the brushes carefully before you remove them to ensure that you know exactly where to put the brushes back in.

Tip: If you aren’t confident you’ll remember where everything goes, take many pictures of the brushes before you remove them. 

Tip: Another popular method is to remove one brush and then immediately replace it with a new one at a time.

4) Use whichever method above you feel is best and replace all your old brushes. 

5) After replacing all your old brushes, use a can of compressed air to clean off all the black dust released during the changing process. 

Warning: Avoid breathing in the black dust released when changing your brushes; the black dust is horrible for your lungs.

Tip: Use a face mask when changing the brushes in your starter generator.

If you need some high quality parts for your generator, visit Golf Cart King

 

How Do You Wire a Golf Cart Starter Generator? 

How you wire your starter generator depends on the model of starter generator that you have. In general, there are two types of starter generators. 

1) Two terminal starter generator.

Two terminal starter generators only work in one direction and the direction depends on how it’s wired internally. The starter generator can be rewired to make it spin in another direction.

2) Five terminal starter generator.

Five terminal starter generators can be externally wired to operate in either direction and don’t have a case ground.

The terminals on a five terminal starter generator are: 

1) A1 and A2. They’re the armature terminals which are connected internally through the brushes to the armature. 

2) D1 and D2. They’re the main field terminals which are connected internally to the main field coils.

3) DF.

The following are instructions on how to wire the starter portion of a five terminal starter generator: 

1) Connect the positive battery terminal to the input side of the starter solenoid.

2) Connect A1 to the output side of the solenoid,

3) Connect A2 to D1. 

4) Connect D2 to the negative battery terminal.

5) Test the rotation direction by energizing the starter solenoid for a moment and observe the direction of rotation.

6) Do this a few times to ensure that it’s turning in the correct direction.

7) If it’s turning in the correct direction, then you’ve got your starter wired properly.  

8) If it’s not turning in the correct direction, you need to swap the main field coil connections (connect A2 to D2 and connect D1 to the negative battery terminal).

The following are instructions on how to wire the generator portion of a five terminal starter generator: 

1) Ensure you have the correct voltage regulator. 

2) It should have 3 or 4 terminals. They are: 

a) FIELD which should be connected to the DF terminal of your starter generator. 

b) BAT which should be connected to the positive terminal of the battery. 

c) LOAD which is used for external loads. 

d) ARM which should be connected to A1 of the starter/generator.

Tip: Use 14 AWG wire for the charging connections and 1 AWG wire for the battery/starter connections.

 

How Do You Test a Golf Cart Starter Generator? 

Here’s a general set of instructions that should work for most golf cart starter generators.

To test the starter generator:

1) Put the neutral lock-out cam in service.

2) Place the forward and reverse lever in neutral.

3) Chock the wheels.

4) Make sure the wires are connected correctly and are adequately tightened. 

5) If the wires aren’t, rewire or tighten them as needed.

6) Remove all the wires from the terminals on the starter generator. 

7) After that, place the black probe (negative) of your multimeter on the starter generator housing. 

8) You will need to hold the black colored probe against the housing. Then place the red probe (positive) on the A1 first, then on the A2, F1, F2 and DF terminals respectively. 

9) The reading should be “no continuity”. 

10) If your readings for A1 or A2 are wrong, it might be one (or more) of three possible problems; a grounded A1 or A2 terminal, a grounded wire in the brush area or a grounded armature/commutator. 

11) If your readings for F1 or F2 are wrong, it might be a grounded F1 or F2 terminal or a grounded field coil. 

12) If your readings for DF are wrong, it might be a grounded DF terminal or a grounded field coil.

13) Remove the ground wire from A2 as well as the green wire from A1.

14) Set your multimeter to ohms (O) then put the red probe (positive) on the A1 terminal and the black probe (negative) on the A2 terminal. 

15) The reading should be “continuity”.

16) If your reading is wrong, an open or poor contact in a brush assembly or open armature windings might be the issue. 

17) Remove the green wire from F1 as well as the white wire from F2

18) Use your multimeter that’s set to ohms and put the red probe (positive) on F1 and the black probe (negative) on F2. 

19) The reading should be “continuity”. 

20) If your reading is wrong, an open field coil or bad connections at the terminals might be the cause. 

21) Remove the yellow colored wire from the DF terminal as well as the green wire from the F1 terminal on your starter generator. 

22) Using your multimeter (set to ohms), put the red probe (positive) on the DF terminal and the black probe (negative) on the F1 terminal. 

23) You should see a reading between 4.5 to 5.5 ohms. 

24) If your reading is wrong, you may have a grounded DF terminal or a grounded field coil.

To test the generator:

1) Put the neutral lock-out cam in service.

2) Move the forward and reverse levers to the neutral position.

3) Chock the wheels.

4) Ensure that all wires are connected tightly. 

5) If not, rewire and/or tighten as needed.

6) Then, remove the yellow wire from the DF terminal on your starter generator. 

7) The connection on the yellow wire must be covered to ensure that the yellow wire will not short out. 

8) Use a jumper wire so you can ground the DF terminal to the A2 terminal. 

9) Use a multimeter set to Volts DC (20v range) and put the red probe (positive) on the positive post of the battery then place the black probe (negative) on the negative post of the battery.

10) Turn the key switch on,and then press on the accelerator to start the engine. 

11) Run the engine full speed. 

12) The reading should show that the voltage is rising on the meter. 

13) If voltage rises, you should test your voltage regulator. If voltage doesn’t rise, your generator needs repair work.

14) You’ll then need to connect your yellow wire to the DF terminal on your starter generator.

Here are general instructions on how to bench test your golf cart starter generator: 

1) Put your starter generator in a vice or make someone hold it carefully. 

2) Attach a 10-gauge jumper wire from F1 to A2.

3) Attach the black (-) battery cable to the negative bettery terminal. 

4) The other end of it should be attached to A1 which is at the back of the starter generator. 

5) Attach the red (positive) battery cable to the positive terminal on the battery. 

6) Touch the other end to F2. 

7) When the positive cable touches F2, the motor should start to spin counter clockwise. 

8) If it spins, it’s working correctly. 

9) If it’s not spinning, then the motor is defective and needs to be replaced.

 

How Do You Test a Yamaha G1 Starter Generator? 

There are four posts on the starter generator that should be labelled A1, A2, F1 and F2. Also, there should be a green wire and a red wire coming out of the side of the starter. 

To test your Yamaha G1 starter generator: 

1) Disconnect all the wires before you begin your tests. 

2) Connect post F2 to the positive terminal of your cart battery and A1 to the negative terminal of your cart battery.

3) After that, when you connect A2 to F1, your starter should spin forward. 

4) When you connect F2 to the positive terminal of the battery and A2 to the negative terminal of the battery as well as connect A1 to F1, your starter should run in reverse.

5) Check the Ohms running through the red and green wires using a multimeter. 

6) Use a multimeter set to Ohms (O) to touch the green wire with one probe and the red wire with the other probe. 

7) The reading should be about 5 Ohms.

 

How Do You Test a Club Car 98 Starter Generator? 

To test your Club Car 98 starter generator: 

1) Put the neutral lock-out cam in the service position. 

2) Move the forward and reverse lever in the neutral position. 

3) Chock the wheels. 

4) Ensure that all wires are connected tightly and correctly. 

5) If the wires aren’t, then rewire and/or tighten them as needed. 

6) Remove all the wires from all the terminals on the starter generator. 

7) Then place the black probe (negative) of your multimeter on the starter/generator housing. 

8) Hold the black probe against the housing, then place the red probe (positive) on the A1, A2, F1, F2 and DF terminals respectively.

9) The readings should be “no continuity”. 

10) Getting an incorrect reading from the A1 or A2 terminal can mean any of three possible problems; a grounded A1 or A2 terminal, a grounded wire in the brush area or a grounded armature/commutator. 

11) Getting an incorrect F1 or F2 reading can possibly mean a grounded F1 or F2 terminal or a grounded field coil. 

12) Getting an incorrect DF reading can possibly mean a grounded DF terminal or a grounded field coil. 

13) Remove the ground wire from the A2 terminal and remove the green wire from the A1 terminal on the starter/generator. 

14) Then, use a multimeter set to ohms (Ω) and place the red probe (positive) on the A1 terminal and the black probe (negative) on the A2 terminal. 

15) The reading should be continuity. 

16) If the reading is incorrect, it’s possible there is an open or poor contact in a brush assembly or open armature windings. It may also be both.

17) Remove the green wire from the F1 terminal and remove the white wire from the F2 terminal on the starter generator. 

18) Using a multimeter set on ohms (Ω), place the red probe (positive) on the F1 terminal and the black probe (negative) on the F2 terminal. 

19) The reading should be continuity. 

20) An incorrect reading can mean a possible open field coil or bad connections at terminals.

21) Remove the yellow wire from the DF terminal and remove the green wire from the F1 terminal on the starter generator. 

22) Using a multimeter set on ohms (Ω), place the red probe (positive) on the DF terminal and the black probe (negative) on the F1 terminal. 

23) The reading should be between 4.5 to 5.5 ohms (Ω). 

24) If the reading is incorrect, a grounded DF terminal or a grounded field coil may be the cause. It’s also possibly both problems.

 

How Do you Test a Club Car Precedent Starter Generator?  

To test your Club Car Precedent starter generator: 

1) Remove the yellow wire from the generator. 

2) Then, using a piece of 14 ga wire with the appropriate eyelet, connect to the terminal. 

3) Touch the battery with the wire while it’s running. 

4) Check the voltage using a multimeter. 

5) The generator is working if you pick up any voltage. 

 

How Do you Test an EZYGO Starter Generator? 

To test your EZYGO starter generator: 

1) Remove the green wire from the regulator while keeping the other end attached to the starter.

2) Ground the wire.

3) Check the voltage using a multimeter.

4) Your voltage reading should go up to around 18 or 19 volts if the starter generator is working properly.

Tip: A common rule of thumb is that if it works as a starter, it should work as a generator. This is not always the case though. 

Tip: The simplest way to test your EZYGO starter generator as a generator is to reinstall it. This is because it has to spin to be tested as a generator.

Ernie

Ernie loves documenting interesting facts about golf.

Recent Content