I’m scratching my head here with my trusty old 36V EZGO. I’m dreaming of amping it up to 48V but really want to avoid a full-scale rebuild. Has anyone pulled this off? I’m looking for some wisdom here to boost my cart’s performance without draining my wallet. Any advice?
Response
I’ve been down this road with my own EZGO. Upgrading to a solid-state controller was a game-changer for me. It wasn’t as pricey as a full rebuild and really kicked up the cart’s performance. Definitely worth considering!
Solutions that Worked for Users
| Solution | Users Who Found Success | Approx. Cost (USD) | Approx. Time Needed (Minutes) |
|---|---|---|---|
| Upgrade to Solid State Controller | 3 | $300 – $400 | 120 – 180 |
| Motor Upgrade or Rebuild | 2 | $250 – $500 | 180 – 240 |
| Replace Solenoid with 48V Compatible | 1 | $50 – $100 | 60 – 90 |
Symptoms
- Golf cart underperforms or lacks desired speed.
- Concerns about the ability of resistor coils to handle increased voltage.
Possible Causes
- Resistor coils and other components not designed for 48V operation.
- Need for more efficient power management and torque.
Solutions that Worked
- Upgrade to Solid State Controller
- What I Did: Replaced the old resistor controller with a new solid-state controller.
- Outcome: Improved efficiency and readiness for higher voltage.
- Personal Experience: The upgrade was a game-changer, offering smoother acceleration and better power management.
- Steps:
- Research and select a compatible solid-state controller. Look for models known for reliability and compatibility with your EZGO model.
- Safely disconnect the cart’s power source. This is crucial to avoid any electrical hazards.
- Carefully remove the old resistor controller. Take note of all connections and wiring for reference.
- Install the new controller, double-checking each connection. Use the wiring notes as a guide.
- Reconnect the power and conduct a thorough test. Start with a slow drive, checking for any unusual noises or behaviors.
- Expert Tip: Consider adding additional cooling mechanisms, like a heat sink, to the controller to enhance its longevity, especially under increased voltage.
- Motor Upgrade or Rebuild
- What I Did: Opted for a motor upgrade to handle the increased voltage.
- Outcome: Enhanced torque and speed capabilities.
- Personal Experience: The motor upgrade complemented the new controller, making the cart feel almost new.
- Steps:
- Determine whether your current motor can be rebuilt for 48V or if a new motor is needed.
- If purchasing a new motor, ensure it’s specifically designed for 48V operation and compatible with your cart model.
- Carefully remove the old motor, keeping track of all connections and mountings.
- Install the new or rebuilt motor, ensuring all electrical connections are secure and the motor is properly mounted.
- Test the cart extensively, paying attention to the motor’s response and any unusual sounds.
- Expert Tip: Regular maintenance of the motor, such as checking brushes and cleaning vents, can significantly improve performance and lifespan, especially after an upgrade.
- Replace Solenoid with 48V Compatible
- What I Did: Swapped out the old 36V solenoid for a 48V compatible one.
- Outcome: Ensured safe operation at higher voltages.
- Personal Experience: This was a necessary change to prevent electrical issues.
- Steps:
- Identify a 48V solenoid that matches the specifications of your golf cart.
- Disconnect the power and carefully remove the old solenoid, noting its wiring.
- Install the new solenoid, ensuring all wires are correctly connected and secure.
- Test the solenoid’s operation by running the cart, checking for smooth engagement and disengagement.
- Expert Tip: Use dielectric grease on the solenoid terminals to prevent corrosion and ensure a solid electrical connection.
Golf Cart Models Where This Worked
- Various EZGO models from the late 70s and 80s, particularly those with resistor controllers.