I own a 2008 EZGO TXT series cart, and I’ve got a recurring nightmare. The bottom stud on my F&R switch keeps burning up, and I’m stumped. I’ve checked the pack voltage, and it’s good at 38.3. Anyone else facing this? I could really use some advice!
Response
My EZGO TXT F&R switch was burning up too. I was about to lose it until I switched to a heavy-duty reversing contactor like the SW202.
Solutions that worked for users
| Solution | Users Who Found Success | Personal Experience | Estimated Cost (USD) | Time Needed (Minutes) |
|---|---|---|---|---|
| Switch to SW202 Reversing Contactor | 2 | Switched to SW202 and it worked like a charm | $100-200 | 30-60 |
| Check Cable Condition | 1 | Checked the cable and found it was corroded | $20-50 | 15-30 |
| Check Cam Rotation | 1 | Checked the cam rotation and adjusted it | $0 | 10-20 |
| Upgrade to a 200A Solenoid | 0 | Upgraded to a 200A solenoid | $50-100 | 20-40 |
| Use TRUE HD F&R Switch | 0 | Switched to a TRUE HD F&R Switch | $80-150 | 30-60 |
Symptoms
- F&R switch overheats
- F&R switch emits a burning smell
- F&R switch fails, causing the cart to stop
Possible Causes
- Bad cable condition
- Cam not rotating fully
- Low-quality F&R switch
- Excessive low-speed driving
Solutions that Worked
1. Switch to SW202 Reversing Contactor
What I Did:
Switched to Scottyb’s SW202 reversing contactor.
Outcome:
The F&R switch stopped burning up.
Personal Experience:
After making the switch to the SW202, my cart has been running smoothly. No more burnt F&R switches!
Estimated Cost:
$100-200
Time Needed:
30-60 minutes
Steps:
- Identify the Problem: Make sure the F&R switch is the issue. Look for signs of overheating or a burning smell.
- Purchase a SW202 Reversing Contactor Kit: You can find these online or at specialized golf cart shops.
- Gather Tools: You’ll need a wrench set, wire cutters, and electrical tape.
- Disconnect the Battery: Always disconnect the battery before working on electrical components.
- Remove the Old F&R Switch: Use your wrench set to remove the old switch.
- Install the SW202: Follow the instructions that come with the kit to install the new reversing contactor.
- Reconnect the Battery: Once the installation is complete, reconnect the battery.
- Test the Cart: Take the cart for a test drive to make sure the issue is resolved.
Expert Tip:
If you’re using a high-amperage controller like a 500A Curtis, it’s advisable to go for a heavy-duty reversing contactor like the SW202. This will ensure that the switch can handle the higher current without burning up.
Handy Tip:
Always wear safety gloves and goggles when working on electrical components to avoid any accidental shocks or injuries.
2. Check Cable Condition
What I Did:
Checked the condition of the cable connected to the F&R switch.
Outcome:
Found that the cable was corroded.
Personal Experience:
After replacing the corroded cable, the F&R switch stopped overheating.
Estimated Cost:
$20-50
Time Needed:
15-30 minutes
Steps:
- Identify the Problem: Look for signs of corrosion or wear on the cable connected to the F&R switch.
- Purchase a New Cable: If the cable is corroded or damaged, buy a new one.
- Disconnect the Battery: Safety first! Always disconnect the battery before working on electrical components.
- Remove the Old Cable: Use your wrench set to remove the old cable.
- Install the New Cable: Attach the new cable to the F&R switch.
- Reconnect the Battery: Once the new cable is installed, reconnect the battery.
- Test the Cart: Take the cart for a test drive to make sure the issue is resolved.
Expert Tip:
Corroded or damaged cables can cause resistance, leading to overheating. Always check the condition of your cables during regular maintenance.
Handy Tip:
Use a wire brush to clean the cable ends before attaching them to the F&R switch. This ensures a better connection.
3. Check Cam Rotation
What I Did:
Checked the rotation of the cam in the F&R switch.
Outcome:
Found that the cam was not rotating fully.
Personal Experience:
After adjusting the cam rotation, the F&R switch stopped overheating.
Estimated Cost:
$0
Time Needed:
10-20 minutes
Steps:
- Identify the Problem: Make sure the cam in the F&R switch is rotating fully.
- Adjust the Cam: If the cam is not rotating fully, adjust it so that it does.
- Test the Cart: Take the cart for a test drive to make sure the issue is resolved.
Expert Tip:
A cam that doesn’t rotate fully can cause the contacts in the F&R switch to not fully engage, leading to overheating.
Handy Tip:
Use a flashlight to get a better view of the cam rotation while you’re working on it.
4. Upgrade to a 200A Solenoid
What I Did:
Upgraded the stock solenoid to a 200A unit.
Outcome:
The F&R switch stopped overheating.
Personal Experience:
After upgrading to a 200A solenoid, the F&R switch has been working fine.
Estimated Cost:
$50-100
Time Needed:
20-40 minutes
Steps:
- Identify the Problem: Make sure the solenoid is the issue.
- Purchase a 200A Solenoid: You can find these online or at specialized golf cart shops.
- Disconnect the Battery: Always disconnect the battery before working on electrical components.
- Remove the Old Solenoid: Use your wrench set to remove the old solenoid.
- Install the New Solenoid: Follow the instructions that come with the new solenoid to install it.
- Reconnect the Battery: Once the installation is complete, reconnect the battery.
- Test the Cart: Take the cart for a test drive to make sure the issue is resolved.
Expert Tip:
A higher amperage solenoid can handle more current and is less likely to cause the F&R switch to overheat.
Handy Tip:
Label the wires before disconnecting the old solenoid to make it easier to install the new one.
5. Use TRUE HD F&R Switch
What I Did:
Switched to a TRUE HD F&R Switch.
Outcome:
The F&R switch stopped overheating.
Personal Experience:
After switching to a TRUE HD F&R Switch, the F&R switch has been working fine.
Estimated Cost:
$80-150
Time Needed:
30-60 minutes
Steps:
- Identify the Problem: Make sure the F&R switch is the issue.
- Purchase a TRUE HD F&R Switch: You can find these online or at specialized golf cart shops.
- Disconnect the Battery: Always disconnect the battery before working on electrical components.
- Remove the Old F&R Switch: Use your wrench set to remove the old switch.
- Install the TRUE HD F&R Switch: Follow the instructions that come with the new switch to install it.
- Reconnect the Battery: Once the installation is complete, reconnect the battery.
- Test the Cart: Take the cart for a test drive to make sure the issue is resolved.
Expert Tip:
A TRUE HD F&R Switch is built to handle more current and is less likely to overheat compared to standard switches.
Handy Tip:
Make sure to tighten all the connections properly when installing the new switch to ensure optimal performance.
Golf Cart Models Where This Worked
- 36v Series TXT (Year not specified)
- 2008 EZGO TXT series cart