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Old 11-01-2015, 11:59 PM   #1
Chris 195 7/8 B&C
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Default 2005 Ezgo series trouble.

Hey guys thank you in advance for helping me figure this one out.

The cart is a 2005 ezgo 36 volt series cart.
upgrades: Alltrax 4855 controller, heavy duty wires and cables, heavy duty solenoid, heavy duty F&R switch, the GE Beast motor, and Scotty's volt meter.

Last year had a problem and diagnosed a bad ITS which fixed that problem with no issues.

Let me start by saying I don't use the cart very often unless its hunting season and where I keep it under a dried in deck its a bit of an incline so when I release the brake it will roll out about 10 feet which I normally do just to not to have to engage in reverse. Couple months ago I turned key on released brake and let it roll back then after a full stop I pressed accelerator getting the solenoid click but cart wouldn't go in forward or reverse. I went to get tools and meter to try and diagnose which took about 10 minutes and upon my return the cart responded to the pedal as it should.
No problems for about 4 uses and a period of about a month. Then it did the exact same thing as above and again after getting tools gathered and again maybe 10 or 15 minutes it responded and drove all day fine.
Last Friday I took the cart for a short 10 minute ride to so I could plug up charger to charge for an afternoon hunting trip. Cart rode fine but when I plugged charger in it took about twice as long as normal for charger to kick in.
Cart charged fine and pack was 38.1 when I loaded it on trailer.
Went to the hunting land, unloaded and drove about a mile to where I was hunting. No problems and none for the last month or so. Parked cart and hunted the afternoon and upon my return the cart wouldn't go, only the solenoid click. Lifted seat again checked all connections which are clean, looked the best I could at the contacts for F&R which look clean, shifted multiple times thinking it wasn't making contact but it appeared to be and found nothing I could point to but of coarse didn't have meter or tools.
Unloaded gear for the walk back to the truck and before leaving tried petal one more time which resulted in cart operating normally. Me messing with it and trying to find something anything wrong with no tools or meter probably again took 15 maybe 20 minutes.

So without being able to put a meter on it while its actually not working is and has been very challenging.
Can any of you experts point me in the right direction or offer any insight as to whats going on?

Again, thank you in advance.
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Old 11-02-2015, 07:32 AM   #2
Sir Nuke
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Default Re: 2005 Ezgo series trouble.

Chris, you are experiencing the HARDEST problem to solve, and intermittent short. the fact that you have "fiddled" with it each time and it started running, there are a few things that got "used" during the process.....and the fact that you had an ITS issue once upon a time, the first thing I would look at would be the micro-switch in the pedal box. The shifting of the F&R back and forth also cycles the two micro-switches there, those would be my next place to look. HOWEVER, you will have to find them NOT WORKING to be able to diagnose them as being bad.
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Old 11-02-2015, 08:54 AM   #3
mgray70
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Default

Also sounds like it could be that 4 pin Molex connector between the ITS and controller. Unplug it and check for a bad connection.
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Old 11-03-2015, 11:22 PM   #4
Chris 195 7/8 B&C
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Default Re: 2005 Ezgo series trouble.

Well this things driving me crazy. Did it again tonight, stranded in the woods.
Walked back to truck and retrieved a meter but had limited tools and it was raining. Not having good enough cell reception to pull up the directions for ITS test I had nephew bring his 4-wheeler to tow it out back to my trailer thinking it would be easier during daylight and at home. As we get back ready to tow cart I hit the accelerator and it runs normal.
Any suggestions?
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Old 11-04-2015, 07:30 AM   #5
Sir Nuke
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Default Re: 2005 Ezgo series trouble.

Chris, one other thing to check, this happened to me as well and just remembered. Look at the back (rear side) of you F&R switch. you will see a 9/16 NUT in the center, its the shaft of the F&R.....tighten it a little, like a 1/4 turn. mine had gotten a tad lose. tigh0teded it up about a 1/4 turn all as good after that.
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