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My manual is for a 1988 2cycle EZ-Go. That's a single-cylinder engine. It lists under trouble-shooting, Starter/Generator:
1. Check connections and wiring.
2. Belt tension
3. Field resistance a. 0.0056 ohms (F1 to F2). This might appear to read "0.0". b. 5.0 ohms (F1 to DF)
4. Armature resistance - 0.0134 ohms, (A1 to A2)
5. Generator output a. Voltage 13.5 to 15.5 b. Amperate 50 amps max, 11 amps continuous at 14 volts
6. Brush length - 16 to 24 mm I can photograph a couple of diagrams from this manual and email them to you if you think they will be of use. 10 years is quite a gap. Anytime I have had an alternator get hot, it's been a failed voltage regulator. A digital multimeter caught one producing upwards of 50 volts D.C. before I replaced it. But you mentioned a couple of wires not connected. That could have an effect on it. The generator should not be hot and they are expensive to replace. Send an email to rodcros at webruler dot com if you need the photos.
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