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Unread 07-29-2014, 02:36 PM   #1
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Default 2004 club car barley moves

Hey guys....Working on a 2004 48 volt club car that stopped working...Batteries are ok...49.1 ....all cables seem to be tight,...solenoid was not clicking...when I jumped the solenoid the cart would move..New solenoid, it clicks now but cart will barely move....I mean a couple feet in forward or reverse....rechecked all cable on battery and motor, all are good...however the wire coil is very hot....
I see this cart has what looks like another solenoid on the left side....could that be the problem...how do you test that one....

Thanks
Bill
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Unread 07-29-2014, 04:01 PM   #2
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Default Re: 2004 club car barley moves

Did you replace with the correct solenoid? Also if the solenoid on the other side has a coil attached to it, that solenoid could be bad and you are trying to run cart using that coil to conduct the current instead of it going through the solenoid.
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Unread 07-29-2014, 06:34 PM   #3
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Default Re: 2004 club car barley moves

Yes sir mrgolf....it is the correct solenoid......the other solenoid does have a coil connected to it that gets very hot.....I think what you are saying is the current is going through the solenoid I replace that wasn't working and is now going through the second one then to the coil....if that's correct...how do I test the second coil to see if it is bad.....I know the first was bad because of no click and it moved when I jumped the big post...

I have worked on carts here in NC in a large campground for years and have gotten pretty good....Just don't like to replace things by guessing....have worked on some older ones that had 5 solenoids but first newer one with two of them...

thanks
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Unread 07-29-2014, 06:41 PM   #4
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Default Re: 2004 club car barley moves

If the coil on the second solenoid is getting hot, the solenoid is likely not working and the coil it's self is carrying the load. Try jumping the large lugs on the solenoid with a battery cable. Hook it where the coil is hooked. This is for testing. If that makes it work then that solenoid is not closing.
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Unread 07-29-2014, 06:45 PM   #5
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Default Re: 2004 club car barley moves

are you sure it is 04 cart ? the 2 solenoid is in the Club Car DS Regen 1999-2002 Wiring
fyi the coil will get hot

Club Car DS Regen 1999-2002 Wiring
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Unread 07-29-2014, 06:52 PM   #6
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Default Re: 2004 club car barley moves

i think the second solenoid is for half speed reverse ... i could be wrong but it looks that way on diagram

as for slow speed it may be the Regen speed sensor is bad
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Unread 07-29-2014, 07:00 PM   #7
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Default Re: 2004 club car barley moves

The second solenoid is part of the regen braking. The way I understand it. I took it off my 99 DS. And took the speed sensor loose.
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Unread 07-29-2014, 08:55 PM   #8
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Default Re: 2004 club car barley moves

ok....so can I or should I by pass the second solenoid..(how do you do it)....also crash test dummy that is the correct wiring diagram for the one Im working on but I doubled check...It is an 04 ser A0041-???? on the plate and the guy said he bout it in 04....not sure what is going on there.....you also mentioned speed sensor....it you test this one like others cant really test it because it want move but couple feet.....

I am interested in the by pass and how it is done if yall think it will run ok without the second solenoid.

Bill
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Unread 07-29-2014, 08:58 PM   #9
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Default Re: 2004 club car barley moves

nope ...
a = club car 36v or 48v
00 is 2000
41 is week of production
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Unread 07-29-2014, 09:05 PM   #10
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Default Re: 2004 club car barley moves

in the "sticky's"

link >>> DS IQ or Precedent Speed Sensor Test
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