Why is My Golf Cart Surging (EZGO/Yamaha/Club Car)

 

Why is My Golf Cart Surging?

A golf cart can be surging due to insufficient fuel levels, damaged motor brushes or a vacuum leak.

• The brushes in the motor are damaged or worn out.
• The MCOR is malfunctioning or a mismatch between the motor and controller results in torque bumps.
• The contacts on the pot pads have burnt out.
• The water level in the batteries is insufficient.
• The batteries or their cables are old and due for a replacement.
• The connector of the speed sensor is not snapped tightly in position.
• The cables connected to the motor and the eyelets have become loose.
• The RPM limiter of the Alltrax controller has reached its limit.

 

Causes of a Surging EZGO Gas Golf Cart

• The rev limiter has reached its maximum limit. To check this, you can fasten the belt followed by jacking the cart and flooring it. Check if the belt makes contact with the top of the primary clutch as well as goes down to the bottom of the secondary clutch. If so, loosening the governor spring can help. If not, you’ll have to take off the cover and check for a broken weight that has to be replaced.
• The cable from the governor below the motor to the butterfly valve on the carburetor has either become loose or is faulty. If it’s a loose connection, tightening it will solve the problem. However, you may have to replace the cable if it’s faulty or damaged.
• The butterfly valve on the carburetor and linkage start to move before you hear the microswitch clicking sound. The linkage and cables must be adjusted so that this switch clicks before the carburetor begins to open up.
• The set screw on the driver’s side of the cart that is used to set the idle mode on the engine has been wound inward excessively causing the throttle to open up. Removing the screw or backing it will solve the problem.
• The starter sets the golf cart in motion when you try to start the cart indicating that the main belt is very tight. Loosening this as much as possible by adjusting the motor mounts and moving the motor towards the axle may solve the problem.
• The throttle cable is very tight causing the golf cart to move at full throttle and when the pedal is pressed. Adjusting this cable is likely to serve as a possible fix.

 

Causes of a Surging EZGO Electric Golf Cart

• One or more batteries in the battery pack may be failing. Identify the bad battery or batteries and replacing it can resolve the issue. Sometimes, it may be a faulty, loose or dirty battery connection that needs to be set right.
• There is a problem with the signal sent out by the throttle because of water in the ITS due to a crack in the throttle sensor. Fixing this will solve the problem.
• There is a sunken contact in the F/R board. Replacing this contact with a new contact will help.
• There is a loose or dirty connection to the solenoid, F/R switch and motor. Tightening these connections or cleaning them as required may help.
• The stock controller has started failing and a replacement should solve the issue.
• The wiring between the IT pedal box and the controller is either moist or corroded. Removing the old wiring and doing a new one may work as a fix to the problem.
• The cables on the solenoid have become faulty and there is a voltage reading on either side of the big posts on the solenoid when the pedal is activated. Consider replacing all the cables of the solenoid and the F/R switch.
• The pot in the pot-box throttle is filled with dust and dirt. Cleaning the pot is a possible solution.

 

How to Fix a Surging EZGO TXT/RXV

The surging in an EZGO TXT/RXV can be fixed depending on what causes the problem. Some ways in which you can solve the problem are as follows.

1. Check and clean the electrical connections to the batteries, solenoid, F/R switch and motor. Make sure they are tight and remove the dirt or dust that must have accumulated around the connectors.
2. Check the battery pack voltage and ensure that it has the required voltage rating. Also, make sure that their connections are intact. This can help to identify a bad battery that needs to be replaced.
3. Check for cracks in the ITS throttle sensor under the floorboard and do a replacement if there are cracks.
4. Inspect the F/R board for sunken contacts and replace them.
5. Check for a faulty or failing stock controller running hot due to a large current draw as a result of large tires. Getting a new controller fitted in place of the old ones should help.
6. Check for corrosion or moisture in the inline connector as well as the wiring between the controller and the ITS box. You may also want to check the ITS box itself. If there is moisture, wipe the moist areas dry. In case of rust, consider getting a replacement of the rusted parts.
7. Check if there is enough slack in the throttle cable and adjust it if needed. If there is no slack, the cart will run at full throttle when you press the pedal lightly. The linkage before the front timing cover must also not be too tight.
8. The connections between the motor and controller are either incorrect or corroded. In case of incorrect connections, redoing them correctly will suffice. However, if there is corrosion, then replacement is the solution.

 

Why Golf Cart is Surging at Low Speeds

A golf cart may be surging due to faulty batteries, faulty battery cables, or because the speed sensor connection has become loose.

1. There are one or more bad batteries or battery cables. Check the battery pack voltage when the cart is stationary. Keep the meter connected and take the same reading again when you drive the cart with mild acceleration. Repeat these two steps for each battery individually. This will help to identify a failing battery that needs replacement. If there are signs of damage to the battery cable, changing them may work.
2. The connector on the speed sensor has become loose. The eyelets or cable connections to the motor could also be loose. Checking these connections and tightening the required ones is likely to stop the surge.
3. The MCOR below the floorboard is wet. Take it off, allow it to dry completely and then fit it back in place.
4. The intake/airbox has come off or has a loose connection. Put the box back in position or tighten the connections depending on what is appropriate to ensure a proper air/fuel mixture. Use this chance to ensure that the air filter and hose clamps are seated properly and the intake hose has no cracks. If there are cracks, get the hose replaced.
5. The zip tie fitted to the governor for increasing the speed is preventing the throttle from getting closed when the pedal is pressed. Loosening this a little may help.
6. The MCOR in the cart has a problem. If the problem stops when you press the pedal about 20 to 30 times with the key off, the MCOR is faulty and must be replaced.
7. The cart has a weak governor spring. When a new spring of the right tension is put in its place, the problem stops.

 

Why is My Yamaha Golf Cart Surging?

Yamaha golf cart can start surging due to a clogged fuel filter, a dirty fuel pump or by using the incorrect igniter for your golf cart.

1. The igniter used may not be appropriate for the golf cart. It’s worth considering replacing the ignitor with one that is intended for your golf cart model.
2. The air cleaner has a small hole or crack that affects its sealing property, which helps the cart to run properly. Replace the cleaner with a stock unit rather than opting for an aftermarket counterpart.
3. The fuel filter is clogged and needs cleaning. There are instances when the fuel pump may be causing the problem. Clean the pump and check its performance. Do a replacement if needed.
4. The float bowl is accumulated with water or dirt. Alternatively, the main jet may be blocked because of old bad gas varnish. Cleaning the float bowl and main jet may be a good idea.
5. The carburetor bowl is misaligned or the gasket is worn out. Fix the bowl back in position and replace the gasket.
6. Check if the pigtail with a white plug and three wires at the end of the motor that is not fitted to the axle is attached to the electrical harness. If not, connect the plug to the harness.
7. Check for the smooth operation of the pedal assembly. If you feel that it’s not smooth, consider lubricating it. Consider doing this either annually or on a half-yearly basis to make the cart run smoothly at a constant speed.
8. The throttle sensor assembly is prone to wear and tear. Taking off the old one and getting a new one fitted should work.
9. The carburetor is loosely fitted. Tightening it back in its position may arrest the surging problem.
10. There is backfiring because of incomplete closure of throttle shaft, improper accelerator cables adjustment, damaged carburetor gaskets or loose connection of the nuts that connect the airbox to the carburetor. Checking out each of these instances and taking appropriate action may fix the problem.
11. There is a crack in the muffler that affects the backpressure. The muffler will have to be replaced.

 

Troubleshooting a Yamaha G2 that Surges

You can follow the steps 1 to 3 given in the above section ’Why is my Yamaha golf cart surging?’ to stop the surging in your Yamaha G2 golf cart. Apart from the above troubleshooting steps, also consider  the following:

• The rear clutch bushing has become dry and is getting locked up.
• Apply grease on the rear clutch assembly. This is shaped like a triangle and is a part of the inner sheave.
• Even if the bushing is completely dry, don’t apply over two pumps of grease.

 

Troubleshooting a Yamaha G16 that surges

You can use the steps given below to troubleshoot a Yamaha G16 that surges.

1. The carburetor is dirty due to dust accumulation. Remove it from its place and clean it thoroughly ensuring that the float bowl and the small air compressor are clean.
2. Disconnect the fuel line and drain off the old fuel. Connect the fuel line back in its original position once again.
3. The cart has a lean low speed that can be set right by loosening the low-speed air-fuel mixture screw until it gets cleared up.
4. The clutch or any of its components may have worn out that when replaced will set the golf cart right.
5. The carburetor linkage is likely to have got hung up on one of the corners of the carburetor. Releasing it will stop the surging.

 

Troubleshooting a Surging Club Car DS/Precedent

Reasons why a Club Car DS or Precedent golf cart is surging:

1. The MCOR may have become old and faulty resulting in no clear signal to the throttle and eventually leading to a fluctuating throttle.
2. The speed sensor at the end of the golf cart motor may be malfunctioning.