Hey everyone, I’m at my wit’s end here. My golf cart’s resistor is getting dangerously hot, and I’m really concerned it’s going to fry something else. Has anyone else faced this issue? If so, how did you fix it?
Response
Hey there, I totally get your frustration. I had the same problem, and let me tell you, checking the solenoid’s contacts was a game-changer.
Solutions that worked for users
| Solution | Users Who Found Success | Personal Experience | Estimated Cost (USD) | Time Needed (Minutes) |
|---|---|---|---|---|
| Check the Solenoid’s Contacts | 1 | Checked contacts and the issue was resolved | $0 | 10-15 |
| Check for Short Circuits | 1 | Checked for shorts and found one | $0 | 10-15 |
| Replace the Controller | 1 | Replaced the controller and it worked | $100-$200 | 30-60 |
| Check the Microswitch in Pedal Box | 1 | Adjusted the microswitch and it worked | $0 | 10-15 |
| Check ITS Voltages at Controller | 1 | Checked voltages and it worked | $0 | 10-15 |
Symptoms
- Resistor is too hot to touch
- Golf cart either doesn’t move or jerks around
- Distinct smell of burning plastic or electrical components
Possible Causes
- Faulty solenoid
- Electrical short circuits
- Malfunctioning controller
- Incorrectly positioned microswitches
Solutions that Worked
1. Check the Solenoid’s Contacts
What I Did:
Inspected the solenoid’s contacts meticulously to ensure they were closing as they should.
Outcome:
The golf cart ran like a dream, and the resistor cooled down.
Personal Experience:
I realized the solenoid’s contacts were misaligned. After some adjustments, the problem was solved.
Estimated Cost:
$0
Time Needed:
10-15 minutes
Steps:
- Turn off the golf cart and disconnect the battery for safety.
- Locate the solenoid, usually near the battery compartment.
- Use a multimeter set to the continuity mode to check if the contacts are closing.
- If the contacts aren’t closing, either adjust them or consider replacing the solenoid.
Expert Tip:
Always disconnect the battery before working on electrical components to avoid accidental shocks.
Handy Tip:
Use a flashlight for better visibility while inspecting the solenoid, especially if it’s located in a hard-to-reach area.
2. Check for Short Circuits
What I Did:
Checked the electrical circuit for any short circuits.
Outcome:
Found a short circuit and fixed it, resolving the issue.
Personal Experience:
I checked the entire electrical circuit and found a short. After fixing it, the resistor stopped getting hot.
Estimated Cost:
$0
Time Needed:
10-15 minutes
Steps:
- Turn off the golf cart and disconnect the battery.
- Use a multimeter to check for short circuits in the wiring.
- If a short is found, repair or replace the affected wire.
Expert Tip:
Always turn off the golf cart and disconnect the battery before checking for short circuits to avoid any electrical hazards.
3. Replace the Controller
What I Did:
Replaced the faulty controller with a new one.
Outcome:
The new controller fixed the issue, and the resistor stopped getting hot.
Personal Experience:
After replacing the controller, the golf cart started running smoothly, and the resistor stopped overheating.
Estimated Cost:
$100-$200
Time Needed:
30-60 minutes
Steps:
- Locate the controller in your golf cart.
- Disconnect the old controller.
- Install the new controller following the manufacturer’s instructions.
Expert Tip:
Always opt for a controller that comes with good tech support and a warranty to ensure long-term reliability.
4. Check the Microswitch in the Pedal Box
What I Did:
Adjusted the microswitch in the pedal box.
Outcome:
The golf cart started running smoothly, and the resistor stopped getting hot.
Personal Experience:
After adjusting the microswitch in the pedal box, the golf cart started running as it should, and the resistor stopped overheating.
Estimated Cost:
$0
Time Needed:
10-15 minutes
Steps:
- Locate the pedal box in your golf cart.
- Find the microswitch and adjust its position.
- Test the golf cart to see if the issue is resolved.
Expert Tip:
A maladjusted microswitch can cause the solenoid to engage when it shouldn’t, leading to overheating issues.
5. Check ITS Voltages at the Controller
What I Did:
Checked the ITS voltages at the controller.
Outcome:
The golf cart started running smoothly, and the resistor stopped getting hot.
Personal Experience:
After checking the ITS voltages at the controller, I found that they were off. Adjusting them resolved the issue.
Estimated Cost:
$0
Time Needed:
10-15 minutes
Steps:
- Locate the controller in your golf cart.
- Use a multimeter to check the ITS voltages.
- If they are off, adjust them according to the manufacturer’s specifications.
Expert Tip:
Incorrect ITS voltages can cause the controller to misbehave, leading to overheating issues.
Uncommon but Crucial Info
- Battery Health: Sometimes, a weak or dying battery can cause electrical components, like resistors, to overheat. Make sure your battery is in good health.
- Wire Insulation: Damaged wire insulation can sometimes cause resistors to overheat. Check the insulation of all wires connected to the resistor.
- Environmental Factors: Extremely hot weather can exacerbate the problem. Make sure your golf cart is stored in a cool, dry place.
Golf Cart Models Where This Worked
- 2003 PDS
- 1996 EZGO TXT DCS
- 1999 Club Car DS 48v
- 2002 Electric Club Car 36V
I hope this guide helps you solve