I’m really getting sick of this problem with my EZGO golf cart. The precharge resistor keeps blowing, and I have no idea how to stop this. I could really use some advice here.
Response
Please have the resistor and solenoid tested as they are the likely cause of your issue.
Solutions that worked for users
| Solution | Users Who Found Success | Personal Experience | Estimated Cost (USD) | Time Needed (Minutes) |
|---|---|---|---|---|
| Remove and Test Resistor | 2 | Removed the resistor and tested the solenoid | $0 | 10-15 |
| Check Solenoid Closure | 1 | Checked the solenoid with a multimeter | $0 | 5-10 |
| Check Cable and Crimps | 1 | Inspected the cable for bad crimps | $0 | 5-10 |
| Clean and Snug Terminals | 1 | Cleaned and tightened the terminals | $0 | 5-10 |
Symptoms
- Resistor keeps blowing or melting
- Golf cart not starting or behaving erratically
- Unusual heat coming from the resistor
Possible Causes
- Faulty solenoid
- Bad cable crimps
- Dirty or loose terminals
- Malfunctioning motor speed controller
Solutions that Worked
1. Remove and Test Resistor
What I Did:
Removed the resistor and tested the solenoid to see if it was functioning correctly.
Outcome:
The solenoid was working fine, and the resistor stopped blowing.
Personal Experience:
After removing the resistor, I used a multimeter to test the solenoid. Everything checked out, and the issue was resolved.
Estimated Cost:
$0
Time Needed:
10-15 minutes
Steps:
- Disconnect the battery to ensure there’s no current flowing.
- Locate the resistor, which is usually near the solenoid.
- Carefully remove the resistor by unscrewing the terminals.
- Use a multimeter to test the solenoid for continuity and resistance.
- Reconnect the resistor and battery, then test the cart.
Expert Tip:
Always wear safety gloves and goggles when working with electrical components. Make sure to isolate the circuit to prevent any accidental short circuits.
2. Check Solenoid Closure
What I Did:
Used a multimeter to check if the solenoid was closing when it was supposed to.
Outcome:
The solenoid was functioning correctly, and the resistor stopped blowing.
Personal Experience:
I used a multimeter to check the solenoid, and it was closing as it should. This helped me rule out the solenoid as the issue.
Estimated Cost:
$0
Time Needed:
5-10 minutes
Steps:
- Disconnect the battery for safety.
- Locate the solenoid, usually near the battery or motor.
- Use a multimeter to check the solenoid’s functionality.
- If the solenoid is not closing, consider replacing it.
- Reconnect the battery and test the cart.
Expert Tip:
Always use a multimeter to check the solenoid’s functionality. A malfunctioning solenoid can cause the resistor to blow. Also, make sure to check the solenoid during different cart operations like accelerating and braking.
3. Check Cable and Crimps
What I Did:
Inspected the cable between the battery (+) and the solenoid for any bad crimps.
Outcome:
Found a bad crimp that was causing the resistor to blow.
Personal Experience:
I noticed a hot spot on the cable, which led me to discover a bad crimp. After fixing it, the issue was resolved.
Estimated Cost:
$0
Time Needed:
5-10 minutes
Steps:
- Turn off the cart and disconnect the battery.
- Inspect the cable for any visible damage or bad crimps.
- Use a crimping tool to fix any bad crimps.
- Reconnect the battery and test the cart.
Expert Tip:
Use a thermal camera to check for hot spots on the cable and connections. This can help you pinpoint the issue faster. Also, consider using marine-grade cables for better durability.
4. Clean and Snug Terminals
What I Did:
Cleaned the terminals and made sure they were snug.
Outcome:
The resistor stopped blowing after the terminals were cleaned and tightened.
Personal Experience:
I used a wire brush to clean the terminals and made sure they were tightly fastened. This resolved the issue.
Estimated Cost:
$0
Time Needed:
5-10 minutes
Steps:
- Disconnect the battery for safety.
- Use a wire brush to clean the terminals.
- Apply a terminal cleaner or dielectric grease for better conductivity.
- Tighten the terminals to ensure a snug fit.
- Reconnect the battery and test the cart.
Expert Tip:
Use a wire brush to clean the terminals and ensure they are tightly fastened. Loose or dirty connections can lead to overheating. Also, consider using a torque wrench for precise tightening.
Golf Cart Models Where This Worked
- DCS EZGO 36V cart
- 2005 48v Club Car Precedent
- 2007 Precedent
- 2009 Club Car DS
- 2013 Club Car Precedent
Extra tips
- If you’re still facing issues after trying these solutions, consider checking the motor speed controller. A faulty controller can also cause the precharge resistor to blow.
- Always put the Run/Tow switch in the Tow position while working on electrical components to ensure safety.