Possible Overheating FNR switch?

griggsz71

lifted my 2003 EZGO 2 months ago. FNR switch looks original but has recently started getting very warm and smells of hot electrical components. Do these go bad over time and is it possibly caused by larger tires I installed?

BGW

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gornoman

Welcome to BGW!

Your big tires are causing the system weak points to show up. You should add 4g welding cable, fresh copper lugs, HD bussbars and fresh contacts in the F/R assembly, and perhaps a HD solenoid.

griggsz71

Thanks, any ideas on the best place to get these items? Is there a chance the F/R switch goes out completely and I'd be better off replacing the entire assembly?

mikesmotortoys

The big question is do you want to replace with OEM or Aftermarket? We can help you with either of the choices

gornoman

Replacing the entire unit is certainly the easiest route. I see too many posts asking why a cart won't run after upgrading to HD components in the F/R switch. They can be tricky to reassemble correctly for the backyard cart mechanic. Also, I would assume that a new HD assembly would have fresh micros attached, which is always a bonus. Perhaps Mike can verify? Mike is a site sponsor and helps to support this forum.

mikesmotortoys

I personally do not like to "upgrade" an old F/R assembly. The board is as important as the parts IMO. A new OEM stock unit as as good or better than most aftermarket "beefed up" units. If you have already seen some heat buildup in your existing unit, then I would be safe to assume that the board may have also seen some damage from it. We replace, not repair - but then again, I warranty all our repairs

PS - Thanks Gorno I appreciate the !!!

griggsz71

Sounds great. I'll give that a try. Best as I can tell the part I'm looking for is item#5070 on your website. It looks like what is currently installed and would fit my 2003. Thanks!

bond007

The contactor bolts heat up in my 97 TXT, I have had to replace the contactor board that it bolts to which is some type of epoxy/fiberglass composite. The bolt cooks the composite and it eventually crumbles and the bolt starts wobbling and not making good contact, which stops everything. If this happens to you I suggest go ahead and upgrade the whole assembly because you have to tear it down to replace that board anyway.

bond007

Since I have upgraded to 48v over the last few days I have talked to more people about the F/R switch because mine was heating up; I need new board and contact bolts; most said only the buss bars are thicker on HD F/R; So I just got a new $22 board with contact bolts included and I plan to order 2 buss bars to put in.

Consequently nothing is heating up as is in the new board and contacts with the 48 volts even on long runs and hills. I think part of my problem was old batteries and worn contactors. The main bolt through the F/R switch was not tight, got looser with wear; I guess I need to check it periodically to keep things snug and contacting tightly.

The new 48v torque is good, vedy vedy guud.