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Unread 06-18-2014, 11:48 AM   #11
Not Yet Wild
Join Date: Jun 2014
Posts: 6
Default Re: solenoid resistor getting hot

Ok, I believe I may have found the problem. In the charging connector there is a small wire connected to something that looks kind of like a tiny lamp. I think it is actually a magnetic switch. When it is unplugged the resistor doesn't get hot, but the cart doesn't run. With the charger plugged in and everything connected the cart still runs, and the manual says it shouldn't do that. So it seems either that lamp looking switch is bad or the controller. Does it sound like I should buy a new charging connector to you? I just don't want to keep buying parts unless required.
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Unread 06-18-2014, 12:12 PM   #12
JohnnieB's Avatar
Join Date: Jun 2011
Location: West Virginia
Posts: 13,444
Default Re: solenoid resistor getting hot

The lamp looking thingy is a magnetic switch (aka reed switch).
Its purpose is to disable the controller so the cart won't move while the charger is connected.
The reed switch caused so many problems (IE: failing when you were out in the middle of nowhere) that EZGO stopped putting them in their carts about 2007 or 2008. (My 2008 cart has a small fuse in that location, rather than a reed switch)

Most guys bypass the reed switch, either when it fails, or before it has the chance of stranding you someplace. See attached.

The problem you are having is the controller is passing amps when it shouldn't be. (Resistor getting hot)

Either the controller is being told to pass amps to the motor while the solenoid contacts are open, or the controller is bad.
Attached Images
File Type: jpg Ezgo Reed Switch bypass.jpg (169.2 KB, 0 views)
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