98 Club Car gas DS cranks won't start voltage drops

[edster1]

gas club car cranks voltage drops 14 plus to 9 wont start then just clicks won't even crank. Battery fully charged, even try with battery boost start on charger.

[golfcartg]

A lot of people quickly jump to replacing the starter generator particularly with a cheap aftermarket option. Before replacing your starter generator, take the time to thoroughly inspect and test your original unit. It might just need a simple repair, saving you money with way better reliability.

The original equipment starter/generator is higher quality and more durable than the inexpensive aftermarket options. Properly testing the starter generator can reveal if it simply needs repair rather than a complete replacement. Often, issues such as worn brushes, faulty connections, or dirty commutators can be fixed relatively easily and cost effectively. If any of them are compromised, it can lead to insufficient power delivery like the voltage drop you are experiencing, the engine can fail to crank or only produce clicking sounds.

In addition to the starter generator, there are other potential causes for the issue you're experiencing. For instance, a fully charged battery that still drops voltage drastically could indicate a problem within the battery cells, connections or cables.

Additionally, make sure the ground connections are solid and clean and the belt is new and tight. Poor grounding can lead to electrical issues that mimic the symptoms of a failing starter generator or battery. Testing the voltage at different points in the circuit can help pinpoint where the drop is occurring, allowing for a more accurate diagnosis. If you have any additional backstory or info you would like to share in regards to what happened leading up to this situation, or if you need guidance performing any tests, feel free to ask!

[edster1]

Golfcartg, Thank you for your comments. I replaced the spark plug and changed to a brand new battery, new posts bolts and cables have a clean connection. Even with the new battery, when depressing the pedal to engage starter my engine now only gives one click and voltage drops 4 v to 9.2. The clutch pulley and belt seems to be frozen as before I was able to move it, but now I can't. Any suggestions besides engine is frozen and shot.... Thank you, edster1

[golfcartg]

A closer inspection may be necessary by removing the starter belt and try spinning the engine by hand. If the engine turns, great, if it feels locked up, it might be seized. This could be due to internal corrosion, a broken or jammed piston, a failed bearing, debris blocking movement, or even a lack of oil causing internal components to seize.

Pour half a cup of WD-40 into the cylinder through the spark plug hole and let it sit for a few days to penetrate and loosen things up. After that, try spinning the engine by hand again. If it still won’t move, use a wrench on the clutch bolt for more leverage. If the bolt tightens without turning the engine, the engine may be locked up and will need to be broken down and inspected.

[golfcartg]

If the engine turns over, you can proceed to test the starter generator using the guide attached to this post

[edster1]

A closer inspection may be necessary by removing the starter belt and try spinning the engine by hand. If the engine turns, great, if it feels locked up, it might be seized. This could be due to internal corrosion, a broken or jammed piston, a failed bearing, debris blocking movement, or even a lack of oil causing internal components to seize.

Pour half a cup of WD-40 into the cylinder through the spark plug hole and let it sit for a few days to penetrate and loosen things up. After that, try spinning the engine by hand again. If it still won’t move, use a wrench on the clutch bolt for more leverage. If the bolt tightens without turning the engine, the engine may be locked up and will need to be broken down and inspected.

Thank you again for all the help. I loosened the starter/generator and good news is the engine pulley turns freely. But the starter is not turning by hand with belt off or just clicks with power hooked up. Does that indicate that it is in need of rebuild (I have changed brushes on other motors, but since seized I believe it is more than brushes). Your thoughts? Ed

[golfcartg]

The fact that your engine pulley turns freely is a positive sign, indicating that the engine itself is not seized. Given that the starter/generator does not turn by hand with the belt off and only clicks when power is applied, it suggests that there may be internal issues within the starter/generator itself. It could indeed need more than just new brushes. Common issues that can cause a starter/generator to seize include a failed armature, worn out bearings, or a stuck commutator.

You can disassemble the starter/generator and inspect these components using the attached guide. Look for signs of wear or damage on the armature and commutator, check the bearings and verify they move smoothly, and inspect the brushes and brush holders for wear or obstruction. If any of these are damaged or worn out, they can prevent the starter from turning properly.

If you decide that a replacement is necessary, be cautious with cheaper aftermarket options. These often have a significantly shorter lifespan, sometimes lasting only up to a year. I've noticed it is usually more cost effective in the long run to either get the original starter/generator repaired or rebuilt, or to invest in an OEM (Original Equipment Manufacturer) replacement.