Hey community, I’m in a real bind here and could use some sage advice. My trusty EZGO cart has been a loyal companion on the greens, but today, the solenoid screw decided to call it quits – snapped right off! Has anyone tackled this before?
Response
I’ve been in your shoes, and it’s no fun. When my solenoid screw broke, I managed to bypass the reed switch, and voilà – it was like breathing new life into my cart. It’s not the most orthodox method, but it worked. Below is a detailed guide with some tried and true fixes that have helped others in our predicament.
Solutions that worked for users
| Solution | Users Who Found Success | Approx. Cost (USD) | Approx. Time Needed (Minutes) |
|---|---|---|---|
| Bypass Reed Switch | 3 | $0 | 10-15 |
| Jump Solenoid | 2 | $0 | 15-20 |
| Solder Connection | 1 | $5 (soldering kit) | 30-45 |
| Use Crimp Connector | 1 | $1 (per connector) | 10-15 |
| Replace Solenoid | 1 | $45 (solenoid cost) | 60-75 |
Symptoms
- Solenoid not activating
- Golf cart won’t start or starts intermittently
- Clicking noise from solenoid area but no engine turnover
Possible Causes
- Broken solenoid screw
- Faulty electrical connections
- Damaged or stuck reed switch
- End-of-life solenoid
Solutions that Worked
1. Bypass Reed Switch
What I Did: I connected the red and white wires that were going to the broken reed switch. Outcome: The cart started working again. Personal Experience: After bypassing the reed switch, my cart was back in action. Estimated Cost: $0 Time Needed: 10-15 minutes
Detailed Steps:
- Locate the reed switch on your EZGO cart. It’s usually near the charging port.
- Identify the red and white wires connected to the reed switch.
- Disconnect these wires from the reed switch carefully.
- Connect the red and white wires together using a wire nut or electrical tape for a secure connection.
- Test the cart to ensure it starts and runs properly.
Handy Tips:
- Use a multimeter to ensure there’s no electrical current before you start working.
- Make sure the connection is secure to prevent it from coming loose during operation.
Expert Insight:
Bypassing the reed switch should only be a temporary fix. It’s meant to get you back on the course while you source a replacement part.
2. Jump Solenoid
What I Did: I used a jumper wire to connect both large posts of the solenoid. Outcome: The cart moved, indicating the solenoid was the issue. Personal Experience: Jumping the solenoid confirmed it was faulty. Estimated Cost: $0 Time Needed: 15-20 minutes
Detailed Steps:
- Ensure the cart is in a safe position and the key is off.
- Locate the solenoid, which is typically near the batteries.
- Identify the two large posts on the solenoid.
- Use insulated jumper cables or a thick gauge wire to connect the two large posts.
- Turn the key to the “on” position and observe if the cart engages.
Handy Tips:
- Wear safety gloves to protect against accidental sparks.
- If the cart runs when the solenoid is jumped, do not leave it connected for long to avoid damaging the controller.
Expert Insight:
Jumping the solenoid is a diagnostic step, not a permanent solution. If the cart runs when the solenoid is jumped, replace the solenoid.
3. Solder Connection
What I Did: I soldered the wire where the small bolt broke off from the solenoid. Outcome: A secure connection was re-established. Personal Experience: Soldering requires a steady hand but provides a strong connection. Estimated Cost: $5 (soldering kit) Time Needed: 30-45 minutes
Detailed Steps:
- Strip the wire to expose fresh metal for a good solder joint.
- Preheat the soldering iron to the appropriate temperature.
- Tin the wire and the solenoid terminal with solder to prepare them for joining.
- Apply solder to the wire and the solenoid terminal, ensuring a good flow and connection.
- Allow the joint to cool without movement for a solid connection.
Handy Tips:
- Use a heat shrink tube over the soldered area for added insulation and protection.
- Ensure the battery is disconnected to avoid any shorts or sparks.
Expert Insight:
Make sure to disconnect the battery before soldering to avoid any shorts or sparks.
4. Use Crimp Connector
What I Did: I used a crimp connector to attach the wire to the solenoid. Outcome: The connection was restored without soldering. Personal Experience: Crimp connectors are a quick and reliable fix. Estimated Cost: $1 (per connector) Time Needed: 10-15 minutes
Detailed Steps:
- Cut off the damaged end of the wire.
- Strip the wire to expose the metal strands.
- Insert the wire into the crimp connector.
- Use a crimping tool to secure the wire in the connector.
- Attach the connector to the solenoid terminal.
Handy Tips:
- Ensure the crimp is tight and secure to prevent any loss of power.
- Use a crimp connector that matches the wire gauge for a snug fit.
Expert Insight:
Choose a crimp connector that matches the wire gauge for a snug fit.
5. Replace Solenoid
What I Did: I replaced the entire solenoid unit. Outcome: The cart started consistently without any further issues. Personal Experience: Replacing the solenoid was straightforward with basic tools. Estimated Cost: $45 (solenoid cost) Time Needed: 60-75 minutes
Detailed Steps:
- Disconnect the battery to ensure safety.
- Remove the wires connected to the old solenoid, taking note of their positions.
- Unbolt the solenoid from the cart.
- Bolt the new solenoid in place, ensuring it’s secured tightly.
- Reconnect the wires to the new solenoid according to your notes or photographs.
- Reconnect the battery and test the cart.
Handy Tips:
- Label each wire as you disconnect it to ensure correct reassembly.
- Check the operation of the new solenoid before putting everything back together.
Expert Insight:
Photograph or label the wires before disconnecting them to ensure correct reassembly.
Golf cart models where this worked
The solutions provided have been applied to various models of EZGO carts, particularly those with similar solenoid setups. Specific models and years were not mentioned in the discussions.