How to Find/Fix a Blown Golf Cart Fuse (That Keeps Blowing)


fixing a blown fuse on a golf cart

 

SAFETY DISCLAIMER: DON’T attempt to fix any fuses and/or electrical issues with your golf cart. The information has not been verified for accuracy.

ALWAYS use the services of a electrician/mechanic. The steps in this guide are for educational purposes only, and should NOT be attempted, as serious injury could occur. 

Do Golf Carts Have Fuses?

Yes, all golf carts have fuses and breakers. Most controllers like Alltrax come with a fuse because having a fuse on the battery pack offers many advantages.

One major advantage of having the fuse is that it offers protection against fire or a short. This is because a fuse can often deliver a current higher than its rated value before it blows up.

A fuse also helps in getting a warranty for the controller.

 

Where is the Fuse Box Located on a Golf Cart?

Where is the fuse box located on a golf cart? Most EZ-GO carts will the fuse located in the charging receptacle. The 2008 EZ-GO TXT gas golf carts have inline fuses that are connected to the key switch.

In 1990 Marathon golf carts the fuse panel is situated behind rubber air intake bellows on the inner body on the passenger side where it’s fitted to the carburetor.

In a 1997 Club Car, the fuse is located in the electrical components black box that is present near the battery. On the other hand, in a 2005 Club Car Precedent, the fuse is connected to a blue wire under the golf cart seat.

 

Why your Golf Cart Fuse Keeps Blowing

A golf cart fuse can blow for many reasons such as a faulty relay switch, loose connections or a naked wire.

There are some reasons why your golf cart fuse tends to keep blowing:

  • There is a naked wire or a grounded wire. Check all connections to see if any of them have come off and connect them once again.
  • There is a dead-short connection after the start switch. Once this is corrected, the fuse will stop blowing up.
  • The starter relay or the start/stop switch on the gas pedal is faulty. When this is replaced with a new one, the problem is sorted out.
  • There may be one or more loose cable connections. Tighten all the loose connections.
  • The terminals of the battery or batteries are connected to the wrong posts. Connect the positive and negative terminals to the right posts.
  • The cable from the key switch has become hot and melted the plastic resulting in a short. Once the short is attended to, the problem will get resolved.
  • There is a problem with the voltage regulator and it indicates an abnormally high voltage. The fuse will stop blowing up when the voltage regulator is replaced. There is also a possibility of the voltage regulator getting shorted internally.
  • The fuse that blows out has a lower rating than what is required. Replacing the fuse with a higher rated one will solve the problem.
  • The starter generator is shorted on the inside and the solenoid remains closed. When the starter is changed, the fuse of the golf cart will stop blowing up.
  • Alternatively, the starter generator wire tends to vibrate and eventually blow out the fuse after grounding.
  • The solenoid tends to click on and off at a very fast rate repeatedly when the pedal is deactivated. Substituting the faulty solenoid with a new one will solve the problem.

 

How to Fix a Blown Fuse on a Golf Cart

You can follow the steps given below to fix a blown fuse on a golf cart using a new replacement fuse and a pair of fuse pliers.

  1. Locate the service panel of the golf cart. This is usually found behind the battery on the driver’s side on the rear fender.
  2. Make a note of the current ratings supported for each fuse at the highest voltage. This is important because the replacing fuse must match the exact current specifications although the voltage can vary.
  3. Look out for the broken fuse. To do this, you must identify the area of the electrical system that isn’t working. This will help you identify which fuse has blown out.
  4. Grasp the fuse with your hands using a pinching action and pull it out. Alternatively, you can use a pair of fuse pliers to help you do this. In some cases, the inside service panel will house a pair of plastic pliers.
  5. Check the fuse to determine its current rating. This rating is usually given on the face of the fuse, in white.
  6. Push the replacement fuse with the same current specifications into the same slot. It’s important to push the fuse in straight as far as it will go to avoid the possibility of a weak connection that results in the fuse blowing up again.

If the fuse tends to blow repeatedly, the golf cart has a major problem with its electrical system. It’s recommended having a professional inspect your golf cart.

 

10-amp fuse

  • The solenoid, if replaced, is not a continuous duty solenoid. If you don’t use a continuous duty solenoid, it tends to burn up when it’s energized. This will, in turn, cause a short and blow up the fuse.
  • There is a break or pinch in the wire insulation for the key ignition. This is behind the panel for a 2006 Club DS cart. Attending to this problem will help to stop the fuse from blowing up.
  • The voltage regulator is hitting the starter generator because of a wiring problem. Unplug the voltage regulator and fix the wiring under it. Once this is done, plug the regulator into its original place and turn it on.
  • There is a short in one or more battery cables connected to the starter generator. When this problem is addressed, the fuse will not blow up.
  • The battery connections in the golf cart are reversed. Correcting the connections can make the fuse stay intact.
  • The ignitor is at fault. Replacing this can work out to be an expensive deal and hence, it’s worth checking out on the voltage regulator first as mentioned above. If you have to do an ignitor replacement, consider opting for an OEM one rather than the ordinary aftermarket counterpart.

 

50-amp fuse

  • The D plug or D receptacle has a miswiring. Check to see that the white and black wires of the plug are connected to the corresponding wires of the receptacle.
  • The diodes have a very high resistance passing through them for forward bias and very low resistance for reverse bias. A replacement of both the diodes will stop the fuse from blowing up. You may have to bore new holes in the aluminum plate that housed the old diodes.

 

60-amp fuse

  • The fuse hasn’t been connected properly. One reason could be that the fuse hasn’t been pushed in to the maximum extent possible or there may be a wiring mismatch.
  • The fuse is used in the high current circuit of the motor connection and is too low for the same. This circuit makes use of a minimum 250A fuse.
  • There is a problem in the wires that are connected to the charger port. Check for a short here between the heavy white and black wires when the golf cart is in motion without attaching the battery charger.
  • The terminals in the receptacle are making contact with each other when the golf cart is moving without fitting a battery charger.
  • The fuse is located in the power circuit instead of the charging circuit. When a fuse is connected to the power circuit, it tends to blow out faster since the current rating will be more than 60 amps. It should be connected to the charger socket on one side and the main battery post on the other side.
  • There is an improper connection between the batteries. Redoing the connections properly will stop the fuse from blowing up if all other connections are intact.

 

400-amp fuse

  • The 400-amp fuse will be located as close as possible to the power source or batteries. It can be placed on either the positive terminal or negative terminal of the battery. This makes it easy to check the fuse than when it’s under the golf cart.
  • Golf carts with an Alltrax controller usually feature a 400-amp fuse fitted on the controller. This fuse must be connected to the positive terminal of the main battery pack.

 

Yamaha Golf Cart Fuse Box Location

The fuse box in a 2014 Yamaha golf cart is located on the left side of the controller. The wires are tied to the roof drain.

In a G2 electric cart, the fuses are present on the rear inner fender. This is on the front of the driver’s side of the cart. They’re round in shape and made of glass.

The blue fuse block in a Yamaha G29 golf cart is below the cup holder and secured on the shelf. It can be accessed by popping out the cup holder using an Allen wrench.

 

EZ-GO Golf Cart Fuse Box Location

The 2008 EZ-GO TXT golf cart uses an inline fuse with a small wire going to the key switch. This wire is present at the point where the big wire of the positive battery terminal is connected to the solenoid.

In a 2005 EZ-GO electric golf cart, the fuse block is located below the driver’s seat. The fuse box in a 1990 EZ-GO golf cart is present in the wheel according to the manual.

 

Club Car Golf Cart Fuse Box Location

The fuses in a 1986 CC DS gas engine golf cart is located behind the dash. The fuse box in a 1997 Club Car can be found in the black electrical component box that is near the battery.

In a 2004 Club Car Precedent, the fuses are located in two black plastic fuse holders that come with a molded support hole extension.

On the other hand, the fuse insert in a 2005 Club Car Precedent is present under the seat with a blue wire attached and is fitted to the light wire harness.

The 15-amp fuse in a 2008 Precedent is located on the rear below the controller harness. This can be accessed by removing the plastic cover above it.

Ernie

Ernie loves documenting interesting facts about golf.

Recent Content