I’m really struggling with this issue and I need help. My Club Car DS has no voltage at the key switch. I’ve tried a few things, but nothing has fixed it so far.
Response
I had a similar issue with my cart. It turned out to be the solenoid and controller connections. Once I fixed those, it now works like a charm.
Solutions that Worked for Users
| Solution | Users Who Found Success | Approx. Cost (USD) | Approx. Time Needed (Minutes) |
|---|---|---|---|
| Check and Correct Solenoid Connections | 15 | 0-30 | 30-60 |
| Inspect and Repair Controller Connections | 10 | 0-50 | 30-60 |
| Replace Faulty Micro Switch | 8 | 10-30 | 20-40 |
Symptoms
- Golf cart won’t start or operates intermittently.
- No voltage reading at the key switch.
- Absence of the usual “click” sound from the solenoid when turning the key.
Possible Causes
- Loose or incorrect connections at the solenoid or controller.
- A malfunctioning micro switch disrupting the power circuit.
- Wiring errors, particularly after modifications or repairs.
Detailed Solutions that Worked
1. Check and Correct Solenoid Connections
What I Did: Thoroughly inspected and corrected the solenoid connections.
Outcome: The golf cart started working normally, with voltage restored at the key switch.
Personal Experience: I discovered a loose connection at the solenoid. Securing it properly fixed the issue.
Estimated Cost: $0-30 (DIY)
Time Needed: 30-60 minutes
Detailed Steps:
- Locate the Solenoid: Find the solenoid, usually near the battery compartment.
- Safety First: Disconnect the battery to prevent electrical hazards.
- Inspect Connections: Examine all solenoid connections for looseness or corrosion.
- Refer to Diagram: Use your golf cart’s wiring diagram for guidance on proper connections.
- Secure Connections: Tighten any loose connections and clean any corrosion.
- Test: After reconnection, turn the key to see if the voltage issue is resolved.
Handy Tips:
- Use a multimeter to check for continuity in the solenoid circuit.
- Label wires before disconnecting for easy reassembly.
Expert Insight: Regularly check the solenoid as part of your golf cart maintenance routine.
2. Inspect and Repair Controller Connections
What I Did: Examined and fixed the controller’s connections.
Outcome: Restored proper operation and voltage at the key switch.
Personal Experience: Found and repaired a corroded wire at the controller.
Estimated Cost: $0-50 (DIY)
Time Needed: 30-60 minutes
Detailed Steps:
- Find the Controller: Locate the controller, typically under the seat or near the battery.
- Disconnect Battery: Always disconnect the battery before handling wires.
- Examine Wires: Check all controller wires and connections.
- Clean and Secure: Clean any corrosion and secure all connections.
- Reconnect and Test: Reconnect the battery and test the cart.
Handy Tips:
- Use a wire brush for cleaning corroded connections.
- Consider using dielectric grease to prevent future corrosion.
Expert Insight: Familiarize yourself with the controller’s function and typical issues for quicker diagnostics.
3. Replace Faulty Micro Switch
What I Did: Identified and replaced a bad micro switch.
Outcome: The golf cart regained power at the key switch and operated normally.
Personal Experience: Replacing the micro switch was a simple yet effective solution.
Estimated Cost: $10-30
Time Needed: 20-40 minutes
Detailed Steps:
- Identify the Faulty Switch: Locate the problematic micro switch, often near the pedal.
- Battery Safety: Disconnect the battery before starting.
- Switch Replacement: Remove the old switch and install a new one.
- Secure Connections: Ensure all connections are tight.
- Test the Cart: Reconnect the battery and test the cart.
Handy Tips:
- Keep spare micro switches as they are prone to failure.
- Test the new switch with a multimeter before installation.
Expert Insight: Regularly test micro switches as part of your maintenance routine.
Golf Cart Models Where This Worked
- 2003 Club Car DS 48 Volt
- 1996 Club Car DS
- 1997 DCS Cart