91 2 stroke Won't start when hot and melts choke cable

[jmertens]

My 1991 EzGo Marathon 2 stroke is having issues. Once it gets hot (ran for about a mile) and I shut it off, when I try to start it again I can here the starter click, but it won't turn over. If I don't do anything it will then melt the choke cable whether the key is on or off. To get this current to stop running through the cable I disconnect the negative terminal and can here the starter click again (seems to release, the belt will move). I think once I disconnect the battery cable and re-connect, the choke cable will not get hot until I hit the gas pedal again...starting the previous mentioned cycle all over again. Once the cart cools off it will then start normally and act normally as long as it is not run for very long. I seem to be able to run 1/2 mile and shut off and start ok. I can run as long as I want without any issues until it shuts off and I try to start again.

I'm not sure where to start on this problem or how to test the issue quick enough I don't melt another choke cable. Seems to me it is a solenoid or starter issue. I'm hoping this description is good enough I can be pointed in the right direction. If there is a thread that has discussed please let me know what to search. Thanks.

[cart around]

You have something shorted to the choke cable. It should not have power near it.

Check the routing. Is it zip-tied to any electrical wires? Is it routed against any power switches?

Do you have good ground cables from the battery to the frame, engine, and FnR switch?

This is a serious fire hazard that needs to be addressed.

[jmertens]

Ground wires seem to be good and connected to frame and engine. I will give it another look and check the FnR switch. New choke cable is routed nicely and secured. I thought I found a wire that was grounding to the choke cable, but I corrected that issue and the problem continues. It is the getting hot and not working that has me confused. I would've thought if the choke cable was grounded to something it would get hot and smoke while running, but it only seems to get hot when I try to restart the machine. It seems to me the generator or the solenoid is grounding out some how, but I'm open to being enlightened on something else. Thanks.

[David Maner]

Originally Posted by jmertens

My 1991 EzGo Marathon 2 stroke is having issues. Once it gets hot (ran for about a mile) and I shut it off, when I try to start it again I can here the starter click, but it won't turn over. If I don't do anything it will then melt the choke cable whether the key is on or off. To get this current to stop running through the cable I disconnect the negative terminal and can here the starter click again (seems to release, the belt will move). I think once I disconnect the battery cable and re-connect, the choke cable will not get hot until I hit the gas pedal again...starting the previous mentioned cycle all over again. Once the cart cools off it will then start normally and act normally as long as it is not run for very long. I seem to be able to run 1/2 mile and shut off and start ok. I can run as long as I want without any issues until it shuts off and I try to start again.

I'm not sure where to start on this problem or how to test the issue quick enough I don't melt another choke cable. Seems to me it is a solenoid or starter issue. I'm hoping this description is good enough I can be pointed in the right direction. If there is a thread that has discussed please let me know what to search. Thanks.

Make sure you have a good ground from starter to battery/frame. During starting the starter will pull more amps than when the S/G is gening

Make sure the paint is off under the ground strap where it connects to the frame

Sound to me like its using the choke cable for the ground.
Anyways hope you get it figured out.

peace

[Cartmaster]

Originally Posted by david maner

sound to me like its using the choke cable for the ground.
Anyways hope you get it figured out.

this!