2004 Club Car - burning smell then died at stop sign, solenoid clicks, lights work

thegriffeths · 01-13-2019, 06:28 PM

Hi everyone! We have a 2004 Gas Club Car Precedent that we now can't get to go. We had smelled burning one day while driving and later when stopped at a stop sign, it would no longer go. The lights work, the back up buzzer works, and we have replaced the battery as well as the solenoid and it clicks when in F or R and stepping on the gas pedal. I've read about F&R switch contacts burning, but all the photos I've seen are for electric engines. Could this be the same? We are able to engage both switches and both will "click" the solenoid. I know next to nothing about golf cart engines, so I really hope you guys can help!

CP241 · 01-13-2019, 06:52 PM

The F/R switch on a gas cart just moves cables to shift a linkage in the transmission. Nothing to burn there. There are wires and a couple micro switches, but one just makes the buzzer work and the other is a safety kill so it only starts in gear.

If the solenoid is clicking then chances are it is fine. Look closely at the starter/generator and if you can get to the brush caps (rubber square covers near the end away from the belt) pull one out and look inside for any signs of burning.

What kind of smell is it? Rubber? Burning electronics? Burning oil?

thegriffeths · 01-13-2019, 08:01 PM

I'm sorry I meant to describe that better. The burning was a metallic burning.

CP241 · 01-13-2019, 08:31 PM

"Metallic" burning is usually electrical. If the solenoid clicks then everything in front of the solenoid is probably okay. If you were driving and it smelled and then when you stopped it wouldn't go again, then I would initially suspect one of 2 thinfs...

1. Starter/generator is smoked
2. Voltage regulator smoked and it blew the main fuse.

Most likely since the solenoid still clicks, the fuse is good so unlikely the regulator, but I've seen them melt wires. I would bet it is the starter/generator. Best to inspect it closely.

If it turns out to be thecause, I would highly recommend an OEM replacement. One of the $100 jobbers on Ebay will likely just lead to more problems.

TahoeDawgZ71 · 01-15-2019, 06:20 PM

CP241 Nailed it. The voltage regulator failed in an overcharging condition. The generator then overcharged the battery and put out way too much voltage for your system to handle. In turn, it burned up the brushes in the starter generator and now it won't start. Definitely invest in an OEM starter generator and an OEM voltage regulator for your cart. Otherwise you'll be fixing it again real soon.

Part numbers: Starter / Generator 103678502
Voltage Regulator 102803301

thegriffeths · 01-19-2019, 12:06 PM

Thank you guys so much! Any recommendations on where to order them and make sure I'm not getting garbage?

Fairtax4me · 01-20-2019, 01:00 AM

Quote:

David Hicks - Owner - Revolution Golf Cars www.RevolutionGolfCars.com

UPGRADE PACKAGES for DS IQ and Precedent, OEM Speed Sensors and MCORS, Lift Kits, and Much More! Call and talk to a human! 706-431-3917

That dude right there^^^

http://www.buggiesgonewild.com/gas-c...ml#post1577775

TahoeDawgZ71 · 01-21-2019, 09:23 PM

Thanks for the referral, Fairtax4me.

Our starter generators are original OEM units with a new pulley included.

01-13-2019, 06:28 PM	#1
thegriffeths Not Yet Wild Join Date: Jan 2019 Posts: 3	2004 Club Car - burning smell then died at stop sign, solenoid clicks, lights work Hi everyone! We have a 2004 Gas Club Car Precedent that we now can't get to go. We had smelled burning one day while driving and later when stopped at a stop sign, it would no longer go. The lights work, the back up buzzer works, and we have replaced the battery as well as the solenoid and it clicks when in F or R and stepping on the gas pedal. I've read about F&R switch contacts burning, but all the photos I've seen are for electric engines. Could this be the same? We are able to engage both switches and both will "click" the solenoid. I know next to nothing about golf cart engines, so I really hope you guys can help!
thegriffeths Not Yet Wild Join Date: Jan 2019 Posts: 3

01-13-2019, 06:52 PM	#2
CP241 Nincompoop village idiot Join Date: Apr 2018 Location: Michigan Posts: 9,673	Re: 2004 Club Car - burning smell then died at stop sign, solenoid clicks, lights wor The F/R switch on a gas cart just moves cables to shift a linkage in the transmission. Nothing to burn there. There are wires and a couple micro switches, but one just makes the buzzer work and the other is a safety kill so it only starts in gear. If the solenoid is clicking then chances are it is fine. Look closely at the starter/generator and if you can get to the brush caps (rubber square covers near the end away from the belt) pull one out and look inside for any signs of burning. What kind of smell is it? Rubber? Burning electronics? Burning oil?

01-13-2019, 08:01 PM	#3
thegriffeths Not Yet Wild Join Date: Jan 2019 Posts: 3	Re: 2004 Club Car - burning smell then died at stop sign, solenoid clicks, lights wor I'm sorry I meant to describe that better. The burning was a metallic burning.
thegriffeths Not Yet Wild Join Date: Jan 2019 Posts: 3

01-13-2019, 08:31 PM	#4
CP241 Nincompoop village idiot Join Date: Apr 2018 Location: Michigan Posts: 9,673	Re: 2004 Club Car - burning smell then died at stop sign, solenoid clicks, lights wor "Metallic" burning is usually electrical. If the solenoid clicks then everything in front of the solenoid is probably okay. If you were driving and it smelled and then when you stopped it wouldn't go again, then I would initially suspect one of 2 thinfs... 1. Starter/generator is smoked 2. Voltage regulator smoked and it blew the main fuse. Most likely since the solenoid still clicks, the fuse is good so unlikely the regulator, but I've seen them melt wires. I would bet it is the starter/generator. Best to inspect it closely. If it turns out to be thecause, I would highly recommend an OEM replacement. One of the $100 jobbers on Ebay will likely just lead to more problems.

01-15-2019, 06:20 PM	#5
TahoeDawgZ71 revolutiongolfcars.com Join Date: Mar 2010 Location: Golf Car Capital of The World... Augusta, Georgia Posts: 10,224	Re: 2004 Club Car - burning smell then died at stop sign, solenoid clicks, lights wor CP241 Nailed it. The voltage regulator failed in an overcharging condition. The generator then overcharged the battery and put out way too much voltage for your system to handle. In turn, it burned up the brushes in the starter generator and now it won't start. Definitely invest in an OEM starter generator and an OEM voltage regulator for your cart. Otherwise you'll be fixing it again real soon. Part numbers: Starter / Generator 103678502 Voltage Regulator 102803301

Today
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01-19-2019, 12:06 PM	#6
thegriffeths Not Yet Wild Join Date: Jan 2019 Posts: 3	Re: 2004 Club Car - burning smell then died at stop sign, solenoid clicks, lights wor Thank you guys so much! Any recommendations on where to order them and make sure I'm not getting garbage?
thegriffeths Not Yet Wild Join Date: Jan 2019 Posts: 3

01-21-2019, 09:23 PM	#8
TahoeDawgZ71 revolutiongolfcars.com Join Date: Mar 2010 Location: Golf Car Capital of The World... Augusta, Georgia Posts: 10,224	Re: 2004 Club Car - burning smell then died at stop sign, solenoid clicks, lights wor Thanks for the referral, Fairtax4me. Our starter generators are original OEM units with a new pulley included.

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