No go g22

[Exfarmer]

I'm having trouble with a g22 that I'm rebuilding for a friend. It is a 2003 cart that had quit running a year ago. He decided to completely rebuild it as it has sentimental value to him. Therfore he bought a new motor, new controller, new solenoid and new li ion 51v battery and asked me to install them. I did but it still won't run.
Here is what has been done:
Admiral MOT- D2 motor installed
New controller
New solenoid
New Vatrer Lifepro battery 51.2v, fully charged
all wires checked for continuity
all wires varified to be connected properly as per wiring diagram.
throttle pot- 4580 omhs across outside terminals, 4750 to 18 ohms sweep(center) to each end. Does this seem right?
The stop switch needs to be replaced but I have shorted across it for test purposes
The tow run switch, main switch, fwd/Rev switch are working properly.

One thing I've noticed is that the solenoid activates as soon as the battery is turned on regardless whether the main switch is on or not. I'm thinking that is not right but can't see why that's happening.
What am I missing? Any and all help would be appreciated.

[Michael Eddie]

That's thoughtful of you, but before we install new equipment, let's diagnose the initial problem. You mentioned the cart stopped running and then sat for a year. What symptoms did you observe before it quit?

Secondly, make use of the technical support offered by the controller and battery manufacturers. Confirm with the controller manufacturer that your controller is programmed for the G22 layout, then contact the lithium battery company for their Yamaha G22 installation guidelines. Report back with your findings.

[RideonTractor]

Well howdy there Mr. ExFarmer! Those kinds of projects can be mighty rewarding, but they can sure test your patience to sometimes!

I've had my fair share of rebuilds and I know sometimes it feels like you're wranglin' a herd of wild horses. But don't you worry you'll get that G22 runnin' smooth as molasses in no time!

[Exfarmer]

That's thoughtful of you, but before we install new equipment, let's diagnose the initial problem. You mentioned the cart stopped running and then sat for a year. What symptoms did you observe before it quit?

Secondly, make use of the technical support offered by the controller and battery manufacturers. Confirm with the controller manufacturer that your controller is programmed for the G22 layout, then contact the lithium battery company for their Yamaha G22 installation guidelines. Report back with your findings.

I do not know what , if any, symptoms it displayed prior to quitting. I do know it he had installed new lead acid batteries, but don't know if that was before or after he had trouble with it. Anyways when the new batteries didn't solve the problem he sold them and the cart sat for a year or so. They then decided to restore it so they bought all the aforementioned parts and engaged me to install them along with a lift kit and new wheels/tires.
The battery is connected up properly. The correct controller was ordered so presumably we received the correct one. I'll try contacting the manufacturer.

[Exfarmer]

Well howdy there Mr. ExFarmer! Those kinds of projects can be mighty rewarding, but they can sure test your patience to sometimes!

I've had my fair share of rebuilds and I know sometimes it feels like you're wranglin' a herd of wild horses. But don't you worry you'll get that G22 runnin' smooth as molasses in no time!

Thanks for the encouragement!

[golfcartg]

One thing I've noticed is that the solenoid activates as soon as the battery is turned on regardless whether the main switch is on or not. I'm thinking that is not right but can't see why that's happening.

Solenoid should cycle upon key "on" or run/tow switch flip so that sounds normal, the solenoid gets its B+ power from the run/tow switch and its B- ground from the controller on a Yami

[cybercart]

Solenoid should cycle upon key "on" or run/tow switch flip so that sounds normal, the solenoid gets its B+ power from the run/tow switch and its B- ground from the controller on a Yami

Yes normally G, but op mentioned it’s cycling with the key off too, something might not be wired right there

[golfcartg]

Exfarmer heres the yamaha g22e troubleshooting guide, let us know how far you can get

[Exfarmer]

Exfarmer heres the yamaha g22e troubleshooting guide, let us know how far you can get

Sorry to be so slow in responding. Thanks for the troubleshooting guide. I went through it twice and couldn't find the problem.
l talked to a tech where we bought the controller and he wasn't much help. His only suggestion was to try a lead ac battery pack instead of the lithium battery. Not sure what that would prove, except the possibility of a bum battery. It is a Valter 51.2v battery, which is supposedlywell made. The controller is an FSIP rebuilt GE. I may try contacting FSIP directly.
If anyone has some ideas, ple share!

[Michael Eddie]

We're here to help and look forward to your response. Please provide more details about your experience with the troubleshooting guide if you can, we're eager to understand how it went. Also, could you share your cart's serial number so we can confirm its make? Additionally, inspect the original charge receptacle and let us know if it uses a 2 wire or 3 wire configuration. Your input will allow us to diagnose potential issues more accurately.

[Exfarmer]

We're here to help and look forward to your response. Please provide more details about your experience with the troubleshooting guide if you can, we're eager to understand how it went. Also, could you share your cart's serial number so we can confirm its make? Additionally, inspect the original charge receptacle and let us know if it uses a 2 wire or 3 wire configuration. Your input will allow us to diagnose potential issues more accurately.

I went through the trouble shooting process twice and everything is within specs.The tag says its a G22E manufacturered in 2003, so yes it is a Yammy. It was a 2 wire.
I found a different, more comprehensive troubleshooting guide on the FSIP site (the controller remanufacturer) and am trying to follow that

[golfcartg]

I went through the trouble shooting process twice and everything is within specs.

That is excellent news, that means the solenoid now clicks as it should and once you get your controller issue/configuration figured out you should be good to go

[Michael Eddie]

You made it through the troubleshooting guide, congrats, that means you have all your controller inputs functioning properly. Now if you're not getting controller output, your controller is bad or your controller configuration/setup may be off. After confirming controller output is established, if it still fails to run, the next step involves providing guidance on how to test the motor

[Exfarmer]

You made it through the troubleshooting guide, congrats, that means you have all your controller inputs functioning properly. Now if you're not getting controller output, your controller is bad or your controller configuration/setup may be off. After confirming controller output is established, if it still fails to run, the next step involves providing guidance on how to test the motor

I think I have finally solved the problem, fingers crossed! It seems like there may be a few poor connections in that 23 pin connector that are making intermittent or no connection. I discovered this when I couldn't get repeatable results when running troubleshooting procedures. A buddy and I discovered that if we manipulated the connector we could get the motor to run. Guess I'll be ordering a new wiring harness.
Thanks for the help. I'll report back when I get the wiring harness installed.