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Unread 01-13-2019, 05:28 PM   #1
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Default 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!
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Unread 01-13-2019, 05:52 PM   #2
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Default 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?
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Unread 01-13-2019, 07:01 PM   #3
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Default 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.
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Unread 01-13-2019, 07:31 PM   #4
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Default 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.
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Unread 01-15-2019, 05:20 PM   #5
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Default 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
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Unread 01-19-2019, 11:06 AM   #6
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Default 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?
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Unread 01-20-2019, 12:00 AM   #7
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Default Re: 2004 Club Car - burning smell then died at stop sign, solenoid clicks, lights wor

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^^^

2004 Club Car - burning smell then died at stop sign, solenoid clicks, lights work
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Unread 01-21-2019, 08:23 PM   #8
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Default 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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