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Electric EZGO Electric EZ GO Marathon, Medalist, TXT and RXV.

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Unread 09-28-2008, 09:55 AM   #1
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Join Date: Sep 2008
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Default melted 4 guage wire

i believe my cart is a marathon? vin plate ends in 94, has split rear seat backs. the 4 guage wire running from the foward/reverse switch to the motor overheats and gets so hot that it melts the plastic sheathing around the wire. my cart has 5" lift, 22" mud tires, 4 guage wire, new batteries. and everything else is stock. just cleaned all the contacts on the foward reverse switch. also does any one know what type of speed controller this cart uses? series, dcs? thanks
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Unread 09-28-2008, 10:22 AM   #2
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Default Re: melted 4 guage wire

Most likely a Series speed control. Your cables melting is a sign of loose connections or bad cables. A switch contact will cause trouble too. Take ALL of them loose one at a time, clean the connection on the cable AND/OR the battery and put them right back on. Don't just look at them and pull on them, TAKE THEM LOOSE and CLEAN the connection.
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Unread 09-28-2008, 11:03 AM   #3
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Default Re: melted 4 guage wire

Welcome to the forum ktb......................
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Unread 09-28-2008, 04:47 PM   #4
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Default Re: melted 4 guage wire

It depends. Resistor or solid state marathons came with either a Curtis 1204 or 1205 controller. The 1205 is a 400amp and was intended for heavy duty application while the 1204 was a regular duty at 275 amps. The 1205 is roughly 9 inches long while the 1204 is around 7 inches long. You can crawl under the cart and look at the bottom of the controller and see it the tag is attached. If still there it will give the Curtis number and have the amps as well.
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