EZGO RXV Won't Move after Voltage Reducer Installation

Rwillden

I bought a used 2008 EZGO RXV from a dealer here in Utah. The cart worked fine for a month and a half. I decided I wanted to install a stereo and move the factory lighting harness over to a 12V reducer, so I purchased an inexpensive 48V to 12V reducer on eBay that was "guaranteed to work." Having worked as a car stereo installer for 4 years, I was confident in my ability to do the job. After flipping the tow mode switch on the cart, and disconnecting the negative lead on the battery, I checked all of my voltages with a MM, and connected the reducer to the battery pack voltage (48v). I connected the 12V sources where they needed to go as well, and the 12V accessories worked as intended. That's where it all went to hell in a handbasket. I turned the cart on, and the cart clicks twice, the reverse horn sounds, but the cart won't move. Oddly enough, (and not even sure it's related) the brake lights are energized whenever I turn the cart to a position other than Off. I called the dealer and they suggested that I bring it into them and they would connect their computer and see what the problem was. After spending a full day diagnosing it and tearing the cart apart (when it was supposed to be a quick thing according to them) they called me back and suggested that I somehow fried the speed controller, and they are now telling me that a new controller will cost $1100. First off, I don't see how anything I could have done would have fried the controller, but either way the cart won't work. One dealer I called suggested that they have had RXV's that when connected to a voltage reducer, the speed control does not respond. I called and asked them to try disconnecting it to see if that fixes the problem, but have not heard back from them. Does anyone else have any suggestions on what this might be? I really can't imagine that following proper procedures for connecting the battery, etc that the speed control fried. On the other hand, I don't have any better answers either.

Thanks in advance for your replies.

BGW

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Rwillden

Update: according to the dealer, they tell me that I inadvertently connected 12v to the potentiometer that has a max voltage of 5v on the speed controller somehow (not sure how... since the only connections I made were to the batteries) but the controller is fried and the accelerator pedal as well. After ordering parts from the internet for $700 less than the dealer quoted me, and paying the dealer a ridiculously high "diagnostic fee" I should be back up and running by the weekend. Fingers crossed. Lesson learned? Instead of saving a hundred bucks, take your cart to the dealer and pay them the extra money to do it right so when the $hit hits the fan, you can blame the dealer, and they have to pay to fix it.

Jerj7907

Not real sure where everything went wrong. I converted my RXV to 6 8 volt batteries so I had to add an inverter to get 12 volts. 1st question How many wires did/does the inverter have? 2nd you are sure you hooked the inverter to the 1st and 4th battery respectively positive and negative like the main power wires are to the controller? 3rd Did you have a switch source to the inverter and if so where was it hooked up to. On my cart that still has 4 12 volt batteries the negative lead is the battery behind the front 3 and under the passenger seating spot is the positive. In the future not sure if you did or not but always disconnect the cart power first. RXV controllers are Temperamental and Expensive to replace as you already know.

Rwillden

It had three wires. 1 for 48V (connected to + on first battery) 1 for 12V Output, and a ground (tied to - on last battery in the pack (the rear one) and ground for 12V). Everything was connected correctly and all 12V accessories work normally. Pretty frustrating. To add insult to injury, the cart that was purchased with a brand new black body from the factory was scratched to piss by all of the components being moved around during the repair... Not happy... We'll see if it improves with the new controller and accelerator pedal.

Jerj7907

I did not buy the Ezgo model inverter but got one from GolfCartKing.com sponsor but products are cheaper on Ebay. Mine has 4 wires the 4th being a switch source. Not sure what happened sounds pretty easy to hook up.

BJD350

Now I am unsure if I should get a voltage reducer. Sorry for the trouble you've gone through Rwillden, seems like a major headache! I just installed a Kicker Amp Stereo system in my RXV and have been on the fence on whether to buy a voltage reducer but now I just may go ahead with using one of the 12volt batteries. Keep us posted on how everything turns out! Hope everything works itself out with the new parts you've had to purchase.

Rwillden

Thanks. I'm beginning to think that the problem was actually related to the aftermarket battery voltage meter that I was initially trying to install. I used a meter at the key switch to see if I could get 48v from the key switch to power the meter to monitor voltage. I ended up sending it back since it was too confusing. I'm not sure if I had a bad meter, or if something else happened that may have backfed voltage where it shouldn't be, but the more I delve into this, that's what I'm suspecting simply for the fact that the voltage reducer is a simple device to wire in. In fact, the voltage reducer works perfect. I wouldn't be so concerned about installing the reducer, but in hindsight, I wish I'd spent the few hundred dollars to have the dealer do all the work and avoid such a costly mistake. The electronics on this cart seem to be very temperamental and sensitive to changes in voltage, etc. it's frustrating to say the least, but I think as long as you know what you're doing, and avoid meddling with the factory cart harness, you should be fine. This has been a very expensive mistake. I'm just glad that I'm doing the repairs myself and saving $500-600 over what the dealer quoted me. Luckily the repairs are plug and play and I don't have to worry about screwing something else up. Good luck with your cart also, and thanks for the condolences. :)

Jerj7907

My local dealer warned me not to wire my inverter to the stock wiring harness ie: key switch as he has had 2 carts controllers burned up by customers using a voltmeter to find a switch source. I installed a switch to my source feed and no problems. I would bet anything that is where your controller got fried. I was told RXV's are real temperamental about isolating a single battery to run accessories. I ran all my accessories off a single battery for about 9 months with no problem, I did however have to constantly monitor each battery and charge the 3rd battery independently to keep the voltage roughly the same for the 4 batteries. I only got the inverter due to switching to an 8 volt battery instead of 12 volts. If I was to stick with 12 volt batteries I would have just added a smaller 5th battery for all accessories and charged it separate as many people do. I just did not want the weight of 7 batteries.

Rwillden

That sounds like what might have happened. I have a new pedal switch coming, and a new controller. I'll swap those out and post the results, but for future reference for anyone considering doing an aftermarket state of charge meter, AVOID IT. It's worth the peace of mind to just plug the factory unit in and not worry about it.