Wires from FNR switch to motor getting VERY hot!

[Santacruzslick]

Hey all, first post on this forum. Just bought my first cart(1999 EZ-GO TXT) a few days ago. Just today I took it for a decent trip of about 10 miles and noticed a problem! There was a burning electrical smell coming from under the seat, I have a lot of knowledge about automotive electric but golf carts are still new to me so I need some help with this one. I found that two wires leading from the FNR switch to the motor are getting VERY VERY hot, hot enough that it hurts to touch them and the rubber insulation is on the verge of melting. The rest of the wires are cool or very mildly warm. What could be causing this? Could it simply be bad connections or is the FNR switch going or gone bad.

Also, when I first purchased the cart I know they replaced the reverse buzzer and it only worked for a day or two before getting very quiet and working intermittently. Is this also a symptom of something? Thanks in advance for the help and you will be seeing much more of me on here as I have some plans for this cart...coming from the award winning show car world I have a disease when it comes to modifying anything on wheels!

[roady89]

Those 2 cables have a bad connection. You need to fix it pretty soon or it WILL get worse, maybe to the point you have to replace parts instead of cables.

[Santacruzslick]

Excellent! Just what I was looking for! I suppose I'll spend some time after work tomorrow cleaning up all the connections and replacing the eye terminals on the ends of the wires. Maybe upgrade to 4 gauge while I'm at it as I've got a ton hanging around from car stereo installs.

[rusty]

Welcome to the forum Santacruzslick................

[Santacruzslick]

Thank you!

[Santacruzslick]

So yesterday I cleaned up all of the connections on the FNR switch and I think it solved my problem! No more melting plastic smell and the wires don't get so hot! They do still get mildly warm though...is this normal?

[DaveTM]

Originally Posted by Santacruzslick

So yesterday I cleaned up all of the connections on the FNR switch and I think it solved my problem! No more melting plastic smell and the wires don't get so hot! They do still get mildly warm though...is this normal?

I'm assuming you have an eZ-GO "Series" cart with the F\R handle right below the seat?

My old F\R switch was (and I think still is) the "weak link" in the series system carts.

To eliminate any future issues of your current setup, you may want to go to ScottyB's web site and purchase a set of "Contactor Switches". I did that many years ago and warm cables are a thing of the past.

[scottyb]

Originally Posted by DaveTM

I'm assuming you have an eZ-GO "Series" cart with the F\R handle right below the seat?

My old F\R switch was (and I think still is) the "weak link" in the series system carts.

To eliminate any future issues of your current setup, you may want to go to ScottyB's web site and purchase a set of "Contactor Switches". I did that many years ago and warm cables are a thing of the past.

YOU WIN You have answered
the longest unanswered question in BGW history. The question you answered was asked 13 and a half years ago. That's a record !

Keep up the good work Dave

[Bama Brad]

Better late than never....I guess