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Unread 04-28-2016, 01:55 PM   #11
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Default Re: 84 Club Car 36 Volt Wide open only as soon as it comes alive

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Originally Posted by 93yellowclubcar View Post
There are five solenoids on the cart and three resistors. There are five microswitches attached to a stepped ramp that are engaged in series as you push the throttle. As you look at the solenoids from driver to passenger side they are solenoids 1-5, 1 is the master.

Microswitch 1 engages solenoid 1 as soon as the pedal is pressed, this nets no movement.

Switch two engages solenoid 2 which is "first gear" and has current flowing through 3 resistors.

Switch 3 engages solenoid 3 which is "second gear" and current flows through 2 resistors.

Switch 4 engages solenoid 4 which is "third gear" and current flows through 1 resistor.

Switch 5 engages solenoid 5 which is "fourth gear" and current flows straight from the batteries to the motor.

Over time, the solenoids tend to fail. It sounds as if your solenoid 5 is possibly welded closed and maybe solenoid one also, and some others are not working. It is a really good idea to check all your microswitches first (simple normally open switch, check with a continuity tester that they close and open when the lever is pressed) and then replace any which are bad. Then replace any bad solenoids, which in your case may be several. It is advisable to replace all 5 at once to cut down on repetitive repairs when the next one goes out, since they have probably been in service since 82 they will be very brittle and are bound to fail soon if they haven't already.
Great explanation!
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Unread 04-28-2016, 06:09 PM   #12
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Default Re: 84 Club Car 36 Volt Wide open only as soon as it comes alive

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Originally Posted by steele View Post
Thanks so much Guys. The whole mission went off without a hitch. Pulled the board out and got it up on the bench. Cleaned all connections up proper,Replaces all sols and most nuts and bolts, put it back in. Presto All speeds work . After a A 2 mile ride to the drive thru for a cold pop and Its Ready for a summer of fun . Thanks again Rick
That's great news!!! Glad you got it going.



G-man, thanks!
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Unread 04-28-2016, 07:00 PM   #13
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Default Re: 84 Club Car 36 Volt Wide open only as soon as it comes alive

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Originally Posted by gornoman View Post
Great explanation!
Sticky material in my opinion...
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