My ezgo golf cart has been a nightmare lately because the solenoid posts keep getting burnt through on the resistor. I’m at my wit’s end trying to figure out what’s causing this and how to fix it. Has anyone elsed dealt with this issue?
Response
I had a similar issue with my 2005 EZGO TXT. It turned out to be a problem with the solenoid and controller compatibility. I upgraded to a 500 amp solenoid recommended for my Alltrax controller, and it solved the problem. You might want to check if your solenoid is correctly rated for your controller.
Solutions that Worked for Users
| Solution | Users Who Found Success | Approx. Cost (USD) | Approx. Time Needed (Minutes) |
|---|---|---|---|
| Upgrade to Compatible Solenoid | 1 | $100 – $150 | 30 – 60 |
| Check and Repair Wiring | 1 | $0 – $50 (if DIY) | 30 – 60 |
| Replace F/R Switch | 1 | $20 – $40 | 30 – 45 |
Symptoms
- Solenoid posts burning through on the resistor.
- Golf cart experiencing power issues or not moving.
- Unusual heating of the solenoid resistor.
Possible Causes
- Incompatible solenoid for the controller.
- Faulty or loose wiring connections.
- Issues with the Forward/Reverse (F/R) switch.
Solutions that Worked
1. Upgrade to Compatible Solenoid
- What I Did: Upgraded to a 500 amp solenoid compatible with my Alltrax controller.
- Outcome: The golf cart operated smoothly without any further issues.
- Personal Experience: After upgrading, I noticed an immediate improvement in performance.
- Steps:
- Research the appropriate solenoid rating for your specific controller model.
- Safely disconnect the power source from your golf cart to prevent any electrical hazards.
- Carefully remove the existing solenoid, noting the connection points for an easy replacement.
- Install the new solenoid, ensuring all connections are secure and correctly placed.
- Reconnect the power and conduct a test run to check for any operational issues.
- Expert Tip: Double-check the solenoid specifications against your controller’s requirements. A mismatch can lead to recurring problems.
2. Check and Repair Wiring
- What I Did: Inspected and repaired any loose or damaged wiring.
- Outcome: Resolved the issue of the solenoid posts burning.
- Personal Experience: Found a short in the wiring that was causing the problem.
- Steps:
- Begin with a visual inspection of all wiring connected to the solenoid and controller.
- Look for signs of wear, corrosion, or damage, especially at connection points.
- Use a multimeter to check for continuity and ensure there are no hidden breaks.
- Repair or replace any faulty wiring, using heat shrink tubing for added protection.
- Test the cart to ensure the issue is resolved and there are no further electrical faults.
- Expert Tip: Regular maintenance checks on wiring can prevent many electrical issues. Consider using dielectric grease on connections to prevent corrosion.
3. Replace F/R Switch
- What I Did: Replaced the Forward/Reverse switch.
- Outcome: The cart started functioning correctly in both directions.
- Personal Experience: The switch replacement was straightforward and effective.
- Steps:
- Locate the F/R switch on your golf cart, typically found under the seat or dashboard.
- Disconnect the power source for safety.
- Carefully remove the old switch, taking note of the wiring configuration.
- Install the new switch, ensuring all wires are connected as they were previously.
- Reconnect the power and test the cart to ensure it operates correctly in both directions.
- Expert Tip: A malfunctioning F/R switch can often be the root cause of directional issues. Regularly test the switch for wear and tear.
Golf Cart Models Where This Worked
- 2005 EZGO TXT