2009 RXV pedal switches

NBE

This is the third attempt to post this. Hopefully the third time is the charm.

Needed to change the pedal switch on the accelerator on my lifted RXV. Got the bright idea that I would change all of the switches and sensors there while I had the cover off. The parts for the brake system will plug and play. At least they appear to be. I haven't changed them yet but looks ok. The accelerator system not cooperating very well

The old switch on the accelerator is wired directly into the wiring harness that goes under the body and connects to more wiring between the batteries and the inside of the body and then goes to the controller. There are two wires on the old switch plug, a red one and a blue one.

The new switch comes with a new wiring harness that has a flat plug on the end that on the old one is wired directly. The new plug has four wires, two red ones and two brown ones.

The switches are not interchangeable, as far as unplugging the old and plugging in the new as they are shaped slightly differently. I'm not sure if the new harness will disconnect from the switch as I didn't want to break it but it seems to not want to come off. Still the shape is different.

Do I cut off the flat plug and splice the new plug into the old harness? This is the red and blue wires. Since the new plug has four wires, not two and I cut the flat plug off, which of the four wires do I use? One red and one brown? If so which of each color do I use? Any ideas to help out?

Pictures to follow.

Thanks,
Brad

BGW

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BobBoyce

Are you sure that you have the correct switch in the correct location? The throttle switch usually just has 2 wires to a single switch. The brake switch however has a NO/NC switch with 4 seperate wires going to a slightly remoted connector. Only 2 wires are used on the other side of the RXV brake harness connector, on the normally closed switch connections.

The switch locations and functional switching positions are different between them. The throttle switch detects high pedal position (zero throttle), while the brake switch does not change state until a specified amount of brake pedal travel is reached.

There were a few slight variations based upon the model year. Pictures would definitely help.

Bob

NBE

Thanks Bob for your reply.

The Service and Parts manual I have shows the exact same part number for both the brake and accelerator switches. Same for the position sensors...same part number for both brake and accelerator. The pictures or drawings in the manual that depict the parts both show the same switch with the flat plug on the end for both brake and accelerator. Perhaps that is where the mistake is made? In the manual? Also when I searched for the part on EZGO website that is the part that shows up. Here is the description from EZGO website:

ITEM # DESCRIPTION AVAILABILITY PRICE QTY
607605 Brake & Accelerator Pedal Switch, RXV In Stock $45.98/ea.

I'm not having much luck with pictures. If I use the manage attachments I'm only able to display one picture even though I'm uploading more than one. Shutterfly not cooperating either right now. I'll post a picture of the new switch flat plug so you can see it. I'll figure out this picture problem soon I hope.

Thanks,
Brad

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BobBoyce

Yes, that photo is of the Brake Switch, with the NO and NC sets of contacts. The brake and throttle encoders are the same. The switches are not. The throttle switch has a different mount location, forward and to the right, and the throttle switch harness plugs onto the switch.

Bob

NBE

I understand what you're saying and you're right. I have another I ordered just like it for the brake. But EZGO is selling that one as the replacement for the accelerator pedal switch. I can't find another such switch listed for the RXV accelerator and if there is one with two wires then does anyone know what the part number is?

Both the accelerator and the brake appear to use the same physical switch but have different harnesses. At least originally. The accelerator switch uses only two of the four prongs (red and blue wires) on that switch while the brake uses all four prongs, hence the four wires (two red and two brown). I suspect that the switch for the brake sends and receives a signal? Or sends two signals, one for brake down and one for not down or in the UP position? Or maybe something similiar.

Still doesn't explain why they are selling it as the replacement for the accelerator pedal switch if this one is strictly for the brake assembly. I guess I'll have to call them Monday to see if they can tell me what the deal is. Maybe they changed the design at some point in time.

I may go ahead and cut off the plug on the new harness and splice it. I think I have the wiring figured out. The worse that could happen is that it would just fail the startup sequence, right? I probably need to replace the old switch plug anyway (the one that connects to the switch) as it is a little discolored inside as it if may have shorted a little. Or got too hot at some point.


Thanks again,
Brad

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NBE

I really thought that this was a simple fix. My kind of luck.

I spent most of the day on the phone with EZGO trying to resolve this matter. First got a guy in parts who spent a good bit of time trying to find a switch with a different connector/harness. He eventually sent me to a tech who didn't answer the phone and after ringing a while went to voicemail. I left a message and after thirty minutes without hearing anything I called EZGO back.

Got the same guy in parts who transferred me again to a tech who told me that I need an adapter and immediately transferred me back to the guy in parts. This was before I could tell him that I needed a new plug or a way to splice this one in as the current plug that connects to the switch is burnt and that an adapter that connects the new harness to the old plug will do me no good.

I then told the guy in parts what the tech told me about an adapter. After a while the parts guy says he can't find any such adapter and that he needed to get with the tech. He took my phone number and said he would have the tech call me back. Never happened so after waiting several hours I again called them back.

This time a lady answered and said she had to have my serial number or she couldn't help me at all. I was not at home and didn't have the number on me. After going back and forth about the serial number, I asked her to transfer me to the gut I talked to earlier and she did.

The same guy says they don't have an answer for me and that the matter was given to the engineering department. Not sure now if I'll ever get the cart running anytime soon. Something that should be so simple has confounded so many.

And in between all of this I had to sit on hold from time to time listening to a recording about how great their customer service is. What a day!

Cart still no closer to running. Well, there's always tomorrow.

BobBoyce

I was looking at the parts manual and I see why they are so confused. The switch part number IS the same, but the switch comes with that little brake adapter harness plugged onto the end of the switch. That harness unplugs off of the switch body, once you do that, the throttle plug that you have will fit in its place. How hard would it have been for them to include a note with the part showing how to remove the brake harness adapter for using the switch in the throttle position. Unless they've changed their design again and done away with the connector on the switch and hard-wired it. You never know with E-Z-GO. Which reminds me...

BobBoyce

The early 2008 brake pedal and throttle pedal harness setups were identical. They changed it to prevent confusion between throttle and brake harnesses. There were mistakes made where techs would get them swapped and you could hit the brake pedal and GOOOO! I forgot reading about that back in 2008 when I went to the dealer to have him order me a new RXV. He showed me a service bulletin about that and told me that he could not order me a new one. I am so sorry that I forgot about that, it would have saved you a lot of headaches.

If you think your connector is damaged, you should be able to use that plug from the adapter harness for parts to repair it. There really should not be any current induced damage to that harness connector. On the throttle side, it's only a sensing switch to detect that the throttle pedal is at zero travel. On the brake side however, full brake coil current passes through the switch.

NBE

Well, spent yesterday on and off the phone with EZGO. Still trying to resolve this problem. I was told to order a switch only...no harness. Part number 612889. I said ok but what about part number 609607. Parts guy says no, that one is for a gas cart. I said that the catalog says for electric RXV accelerator pedal and gas RXV turn signal. He says I definitely need 612889, Accelerator Molex Switch. I sent a picture of mine and said 609607 looks exactly like mine and 612889 looks slightly different. Sales guy say you need 612889.

So after ordering 612889 and having it sent overnight, it arrived this morning. Went outside to install the switch and guess what? It didn't fit. The plunger on 612889 is about 1/4 inch longer than my old switch. You have to depress the accelerator all the way down just to install the switch. When you release the pedal back to the up position the switch does not disengage because the plunger is too long..it stays pressed in somewhat.

Called EZGO back and they transferred me to a mechanic. At least he used to work on the carts but has moved up in the organization. After a lot of discussion and me sending pictures he says I need part number 609607.

So I've ordered it and it's coming overnight also. Ny now I have over $100 in shipping costs for all of these "wrong" parts. I guess we'll see if I'm finally lucky enough to get this cart running again.

By the way, I filled out one RMA request last night and have to do another one for today's wrong part in order to return the parts. From talking with them and reading their return policy, they seem reluctant to want to take parts back. Guess I'll see how this works out later on.

It really irks me (or worse really) that I've spent so much on shipping and keep getting parts that do not fit but was bought because on their advice and recommendation. I really needed this cart running last weekend so I'm getting desperate.

More to follow I'm sure. Hope it is good news for a change.


Brad

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BobBoyce

Hopefully that'll fix it. If it wasn't such a pain to get at and pull the pedal cover, I would have taken a look at mine to see. It's been a few weeks since I put it back together after putting in the new 350 Amp controller.

Bob