EZGO F/R Switch Meltdown

snowpuk

I have a 2005 Ezgo TXT....fleet...the cart has been mostly redone, paint, lift kit, knobby tires, flip seat, brush bar, head n tail lights, horn.......anyway...the motor had been upgraded n refurbushed by the factory.....pretty speedy now. But the F/R switch gets really hot....and wires to it from the motor are so hot i think they might melt. Smell like its on fire too, burnt smell......so...the controller seems warm too..275 amps.
Replaced F/R switch with a heavy-duty one, put a new HD Solenoid on, and upgraded all wire to #4 gauge.
Do you think this will do the trick.....will the controller run a lil-cooler because of the #4 wires that replace #6 wire. Not interested in more speed, goes pretty good, just don,t wanna burn everything up. Anything else i should consider, trying to keep cost down by using existing controller.
Has new battery`s....cables up there are real cool. Any advise appreciated........

BGW

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dougmcp

IMO the controller's too small for the job, it should be 400 amp or more.
If you leave the controller in there, you will be replacing it soon. I would order a new one and sell that one while it still has some life.
Rebuild the F-N-R switch with new contacts and HD buss bars.

COURTESYCART

More than likely you have the orig #6 wires on that cart. They are 5+ years old. they needed to be changed.

Going to #4 helps in keeping things cooler. If the motor was rebuild for more pwr/tq than you controller is a time bomb waiting to go off.

snowpuk

OK,,,finished upgrade to F/R switch...HD....and HD Solenoid....replaced wires with #4 gauge wires...been running a lot cooler now. The F/R switch is even cold to the touch.....my wires being 5 yrs. old was part of the problem....its a 2005 TXT as i said in earlier post.
Seems to have a lil-more get up n go too....so far so good. thanks for the information on here..it help figure my problem out.
The controller seems to run a lil-cooler to......good...

scottyb

You Ezgo Guys keep buying complete F&R switches when you you don't have to. What do they cost $150 - $190? All you need is Scottyb's HD ultra conductive Switch Cam For 1/4 or 1/3rd the cost.... the rest of what you are buying is not needed stock equipment....

rabbitreborn

Scotty, we like seeing all the shiny new parts that we get with the new complete unit......

scottyb

I'm gonna spend all evening polishing up my switch cams ....

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Ezgo 1979

ScottyB - Where does a Ezgo lover get that part at?

Sir Nuke

From Scotty.....

scottyb

This thread is 7 yrs old.
I discontinued the HD Switch cam because people were trying to use them to repair damaged F&Rs which is not possible.
The only way to get my HD Switch cam today is in my HD F&R EZ575 ( ps : 2017 switch cams are heavier duty than ever)
Thanks for asking