My golf cart micro switch keeps shorting out

I’m having a problem where my EZGO golf cart micro switch is constantly shorting out, and I’m burning through replacements. It’s seriously affecting my ability to use the cart. Has anyone else had this issue?

Response

It sounds like your diode might be the culprit. A diode installed the wrong way or a shorted one can wreak havoc on your micro switch. It’s worth checking out before you replace another switch.”

Detailed Solutions that Worked for Users

Solution	Users Who Found Success	Approx. Cost (USD)	Approx. Time Needed (Minutes)
Diode Check and Replacement	15-20	10-30	30-45
Solenoid and Battery Check	10-15	0-20	20-30
Inspecting and Testing the Resistor Coils	5-10	0-30	30-60

Symptoms

• Constant shorting of the golf cart’s micro switch.
• Golf cart fails to run unless the motor is bypassed.
• Solenoid making unusual noises or not engaging correctly.

Possible Causes

• Incorrectly installed or faulty diode.
• Issues with the golf cart’s battery or solenoid.
• Damaged or malfunctioning resistor coils.

Comprehensive Solutions

1. Diode Check and Replacement

• What I Did: Inspected and, if necessary, replaced the diode in the circuit.
• Outcome: Resolved the micro switch shorting issue.
• Personal Experience: Replacing a diode that was installed backward fixed the problem.
• Estimated Cost: $10-30
• Time Needed: 30-45 minutes
• Detailed Steps:
  1. Safety First: Disconnect the golf cart’s main power source.
  2. Locate the Diode: Find the diode in the electrical circuit (usually near the solenoid).
  3. Diode Testing: Use a digital multimeter in diode mode to test for continuity. A faulty diode will show no reading in one direction.
  4. Replacement: If the diode is backward or shows no continuity, replace it with a new one, ensuring correct orientation.
  5. Reconnect and Test: Reconnect the power and test the cart.
• Expert Tip: Use a diode with the same or higher voltage and current rating as the original. Ensure the band on the diode matches the circuit diagram’s orientation.

2. Solenoid and Battery Check

• What I Did: Conducted a thorough check of the solenoid and batteries.
• Outcome: Identified and rectified solenoid or battery-related issues.
• Personal Experience: Discovered a weak battery causing solenoid malfunction.
• Estimated Cost: $0-20 (testing), additional for parts
• Time Needed: 20-30 minutes
• Detailed Steps:
  1. Solenoid Test: Listen for a distinct click from the solenoid when the pedal is pressed. No click indicates a problem.
  2. Battery Voltage Test: Use a multimeter to check each battery’s voltage. Low voltage can indicate a failing battery.
  3. Battery Connections: Ensure all connections are clean and tight.
  4. Solenoid Replacement: If the solenoid is faulty, replace it with a compatible model.
• Expert Tip: Regularly clean and tighten battery connections to prevent power issues. Use a battery tester for more accurate readings.

3. Inspecting and Testing the Resistor Coils

• What I Did: Examined and tested the resistor coils for damage.
• Outcome: Fixed issues caused by faulty resistor coils.
• Personal Experience: Found and replaced a burnt coil.
• Estimated Cost: $0-30 (inspection), additional for parts
• Time Needed: 30-60 minutes
• Detailed Steps:
  1. Locate Resistor Coils: Find the coils, usually near the controller.
  2. Visual Inspection: Look for signs of burning or damage.
  3. Continuity Test: Use a multimeter to test each coil for continuity.
  4. Replacement: Replace any damaged coils with compatible ones.
• Expert Tip: Regularly inspecting the coils can prevent unexpected failures. When replacing, ensure the new coils match the specifications of the originals.

Golf Cart Models Where This Worked

• Various models, including 1979 E-Z-GO, 1992 EZGO, and 2004 EZ-GO TXT.