I’ve got an EZGO, and recently, I’ve been hit with a nasty surprise. After a leisurely ride, I caught a whiff of something burning, only to discover the wire to the F/R switch was charred! This isn’t just about the cart smelling like a bonfire; I’m worried about safety hazards and the possibility of getting stranded mid-round. Has anyone else wrestled with this issue? What did you do to fix it?
Response
I had the same burnt wire with my 2004 EZGO Electric TXT. Noticed the solenoid and the main + wire getting unusually hot, followed by that dreaded burning smell. My quick fix? Swapped out the F/R switch with a spare from another cart and changed the solenoid. It was a stopgap that got rid of the smell and got the cart moving again. Definitely check those connections and maybe think about upgrading to more robust parts.
Solutions that worked for users
| Solution | Number of Users Helped | Approx. Cost (USD) | Approx. Time Needed (minutes) |
|---|---|---|---|
| Upgrade to Heavy-Duty Switch and Solenoid | 5 | $150 – $200 | 60 |
| Clean and Secure All Connections | 3 | $0 – $10 | 30 |
| Replace with Continuous Duty Solenoid | 2 | $50 – $75 | 45 |
| Swap F/R Switch from Parts Cart | 1 | $0 (if available) | 30 |
1. Upgrade to Heavy-Duty Switch and Solenoid
Detailed Steps:
- Research and Purchase: Start by researching heavy-duty F/R switches and solenoids that are compatible with your EZGO model. Aim for reputable brands known for durability.
- Safety First: Always disconnect the battery before beginning any work to prevent electric shock.
- Removal: Carefully remove the existing F/R switch and solenoid. Take photos or notes of the wire placements for future reference.
- Installation: Install the new heavy-duty components, double-checking all connections are secure and correctly placed according to your notes or photos.
- Testing: Once everything is hooked up, reconnect the battery and give your cart a test drive to ensure the issue has been resolved.
Handy Tips:
- Use dielectric grease on the connections to prevent corrosion.
- Consider upgrading the wires to heavier gauge ones to complement the new heavy-duty parts.
Expert Insight:
Upgrading not only solves the immediate problem but also enhances the overall resilience of your cart’s electrical system, reducing the likelihood of similar issues in the future.
2. Clean and Secure All Connections
Detailed Steps:
- Identify Connections: Locate all connections related to the F/R switch and solenoid.
- Disconnect and Clean: Using a wire brush or sandpaper, clean each terminal after disconnecting. This removes any corrosion or residue that could cause issues.
- Reconnect Securely: Reattach each wire firmly, ensuring a snug fit to prevent any loose connections which could lead to overheating.
- Operational Test: With all connections clean and secure, test the cart for any signs of electrical issues.
Handy Tips:
- A small amount of electrical contact cleaner can help remove stubborn grime and improve conductivity.
- Regularly inspect and tighten connections as part of your maintenance routine to avoid future problems.
Unique Info:
Loose or corroded connections are often overlooked culprits behind electrical issues in golf carts. Addressing them can preempt a host of problems.
3. Replace with Continuous Duty Solenoid
Detailed Steps:
- Select the Right Solenoid: Ensure the solenoid you purchase is specified as “continuous duty” and matches your cart’s specifications.
- Battery Disconnection: Safety first—disconnect your cart’s battery.
- Old Solenoid Removal: Take out the old solenoid, carefully noting the arrangement of wires.
- New Solenoid Installation: Fit the new solenoid in place, reconnecting the wires as they were previously arranged.
- System Check: Reconnect the battery and test the cart to confirm the new solenoid functions correctly without overheating.
Handy Tips:
- Labeling wires before disconnection can simplify the reinstallation process.
- Check for any signs of wear or damage on the wires during this process and replace if necessary.
Expert Insight:
Continuous duty solenoids are designed to endure the constant electrical load of a golf cart, making them a crucial upgrade for preventing wire burnout.
4. Swap F/R Switch from Parts Cart
Detailed Steps:
- Source a Replacement: Identify a compatible F/R switch from a donor or parts cart.
- Preparation: Before starting the swap, ensure the battery is disconnected to avoid any electrical hazards.
- Switch Exchange: Carefully remove the burnt switch and replace it with the donor switch, paying close attention to the wire connections.
- Final Checks: After the switch is securely in place, reconnect the battery and conduct a thorough test to ensure everything is working as it should.
Handy Tips:
- A visual inspection of the donor switch for any signs of wear or damage can save time and effort in the long run.
- Applying a thin layer of electrical grease on the switch terminals can help prevent future corrosion.
Unique Info:
Utilizing parts from a donor cart is an economical solution but should be seen as a temporary fix until a more permanent solution can be implemented.