Help! The brushes are stuck in my electric golf cart

The brushes in my electric golf cart’s motor are stuck, and it’s causing all sorts of issues. The cart is running intermittently, and I’m not sure what to do.

Response

I’ve been down this road with my own electric golf cart. One thing that really helped with the stuck brushes me was taking the motor apart and giving it a good cleaning.

Solutions that worked for users

SolutionUsers Who Found SuccessPersonal ExperienceEstimated Cost (USD)Time Needed (Minutes)
Remove and Clean the Motor1Cleaned corroded brushes$030-60
Take to a Local Motor Shop1Had motor serviced$50-$10060-120
Replace Brush Holder and Springs1Replaced brush holder$20-$5030-60

Symptoms

  • Golf cart runs intermittently
  • Sudden loss of power while driving
  • Unusual grinding or screeching noises from the motor

Possible Causes

  • Worn out or corroded brushes
  • Damaged or misaligned brush holders
  • Motor issues, possibly related to the armature or field coils

Solutions that Worked

1. Remove and Clean the Motor

What I Did:

Removed the motor and cleaned the corroded brushes.

Outcome:

The cart started running smoothly.

Personal Experience:

After cleaning the corroded brushes, the cart started running fine again.

Estimated Cost:

$0

Time Needed:

30-60 minutes

Steps:

  1. Disconnect the Battery: Always start by disconnecting the battery to prevent any electrical accidents.
  2. Remove the Motor: Use the appropriate tools to remove the motor from the cart.
  3. Open the Motor Casing: Unscrew the casing to expose the internal components.
  4. Inspect the Brushes: Look for signs of corrosion or wear.
  5. Clean the Brushes: Use a wire brush or sandpaper to clean off any corrosion.
  6. Reassemble and Test: Put everything back together and reconnect the battery to test.

Expert Tip:

Use a can of compressed air to blow out any dust or debris inside the motor. This can help improve performance.

2. Take to a Local Motor Shop

What I Did:

Took the motor to a local shop for cleaning and servicing.

Outcome:

The cart started running smoothly.

Personal Experience:

The local shop did a great job cleaning and servicing the motor.

Estimated Cost:

$50-$100

Time Needed:

60-120 minutes

Steps:

  1. Identify a Reputable Shop: Look for reviews or get recommendations for a reliable motor shop.
  2. Remove the Motor: As in the first solution, remove the motor from the cart.
  3. Transport to the Shop: Safely transport the motor to the shop for servicing.
  4. Discuss the Issue: Clearly explain the problem to the technician.
  5. Pick Up and Reinstall: Once the service is done, reinstall the motor.

Expert Tip:

Always ask for a service summary to understand what was done to the motor. This can be useful for future reference.

3. Replace Brush Holder and Springs

What I Did:

Replaced the brush holder and springs.

Outcome:

The cart started running smoothly.

Personal Experience:

After replacing the brush holder and springs, the cart started running fine again.

Estimated Cost:

$20-$50

Time Needed:

30-60 minutes

Steps:

  1. Order Parts: Make sure to order the correct brush holder and springs for your cart model.
  2. Remove the Motor: As before, remove the motor from the cart.
  3. Open the Motor Casing: Unscrew the casing to access the internal components.
  4. Replace the Holder and Springs: Remove the old brush holder and springs and install the new ones.
  5. Test: Reassemble the motor, reinstall it, and test to see if the issue is resolved.

Expert Tip:

Use a digital camera or smartphone to take pictures at each step of the disassembly. This will make reassembly much easier.

Golf Cart Models where this worked

  • 2009 Ezgo PDS 48v
  • Mid-2000s TXT with a series motor
  • 1993 36-volt project cart

Extra tips

  • Lubrication: Sometimes, the brushes may be stuck due to lack of lubrication. A few drops of a non-conductive lubricant can sometimes free them up.
  • Brush Material: Not all brushes are made the same. Carbon brushes are generally better and last longer than other types.

Ernie

Ernie loves documenting interesting facts about golf.

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