ezgo sputtering

green okie · 04-03-2021, 10:29 AM

I have a 98 ezgo txt series drive 36 volt, that sputters when you push on the accelerator pedal.
I installed brand new batteries and replaced the curtis speed controller and new 2G cables. I've checked the connections on the motor, speed controller, solenoid, F/R switch. The solenoid clicks.
It still sputters when you push on the accelerator pedal. It acts like it has power for second then looses power, then power again, then losses power, etc..
Any ideas what could be causing this?

kgsc · 04-03-2021, 10:44 AM

Could be a motor brush issue. I would test the motor to see if it runs smoothly. https://buggiesgonewild.com/showthread.php?t=110856

green okie · 04-03-2021, 12:23 PM

Forgot to mention that it sputters in forward and reverse. Also on flat level ground it sputters but it sputters really bad on hills or inclines. I assume because it is under a load at that point.
I do have a spare used working motor I can switch out.

green okie · 04-04-2021, 12:15 PM

So switched out the motor and the cart still sputters. So it's not a motor related issue.
Visually inspected the pedal box and back tracked the wires and checked 4 pin molex connection. Everything visually looks good.
When the pedal is pushed the micro switch is engaging the solenoid.
When it sputters I can hear the solenoid clicking rapidly. It acts like it has power for second then looses power, then power again, then losses power. Each time the solenoid is clicking.
Is it possible the inductive throttle sensor is working intermittently or possibly the solenoid?

kgsc · 04-04-2021, 01:04 PM

If the solenoid is chattering it could be getting to low a voltage to latch or its contacts might be worn out. With the cart on stands jumper the main lugs and see if the stuttering goes away. If yes change the solenoid.

green okie · 04-04-2021, 01:28 PM

kgsc,
First of all thank you very much for the help.
Let me make sure I understand what you are saying.
Put the cart on jack stands, disconnect the negative battery cable. Then use jumper wires from the batteries to the two large terminal studs on the solenoid. And the solenoid should only click once.
Is that correct?

kgsc · 04-04-2021, 01:39 PM

NO! That would be a direct short.. Run a jumper from the one large solenoid lug to the other large lug. This will act like closing the solenoid.

04-03-2021, 10:29 AM	#1
green okie Not Yet Wild Join Date: Apr 2016 Posts: 16	ezgo sputtering I have a 98 ezgo txt series drive 36 volt, that sputters when you push on the accelerator pedal. I installed brand new batteries and replaced the curtis speed controller and new 2G cables. I've checked the connections on the motor, speed controller, solenoid, F/R switch. The solenoid clicks. It still sputters when you push on the accelerator pedal. It acts like it has power for second then looses power, then power again, then losses power, etc.. Any ideas what could be causing this?
green okie Not Yet Wild Join Date: Apr 2016 Posts: 16

04-03-2021, 10:44 AM	#2
kgsc Gone Wild Join Date: Dec 2009 Location: Aiken, SC Posts: 13,141	Re: ezgo sputtering Could be a motor brush issue. I would test the motor to see if it runs smoothly. https://buggiesgonewild.com/showthread.php?t=110856

04-03-2021, 12:23 PM	#3
green okie Not Yet Wild Join Date: Apr 2016 Posts: 16	Re: ezgo sputtering Forgot to mention that it sputters in forward and reverse. Also on flat level ground it sputters but it sputters really bad on hills or inclines. I assume because it is under a load at that point. I do have a spare used working motor I can switch out.
green okie Not Yet Wild Join Date: Apr 2016 Posts: 16

04-04-2021, 12:15 PM	#4
green okie Not Yet Wild Join Date: Apr 2016 Posts: 16	Re: ezgo sputtering So switched out the motor and the cart still sputters. So it's not a motor related issue. Visually inspected the pedal box and back tracked the wires and checked 4 pin molex connection. Everything visually looks good. When the pedal is pushed the micro switch is engaging the solenoid. When it sputters I can hear the solenoid clicking rapidly. It acts like it has power for second then looses power, then power again, then losses power. Each time the solenoid is clicking. Is it possible the inductive throttle sensor is working intermittently or possibly the solenoid?
green okie Not Yet Wild Join Date: Apr 2016 Posts: 16

04-04-2021, 01:04 PM	#5
kgsc Gone Wild Join Date: Dec 2009 Location: Aiken, SC Posts: 13,141	Re: ezgo sputtering If the solenoid is chattering it could be getting to low a voltage to latch or its contacts might be worn out. With the cart on stands jumper the main lugs and see if the stuttering goes away. If yes change the solenoid.

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04-04-2021, 01:28 PM	#6
green okie Not Yet Wild Join Date: Apr 2016 Posts: 16	Re: ezgo sputtering kgsc, First of all thank you very much for the help. Let me make sure I understand what you are saying. Put the cart on jack stands, disconnect the negative battery cable. Then use jumper wires from the batteries to the two large terminal studs on the solenoid. And the solenoid should only click once. Is that correct?
green okie Not Yet Wild Join Date: Apr 2016 Posts: 16

04-04-2021, 01:39 PM	#7
kgsc Gone Wild Join Date: Dec 2009 Location: Aiken, SC Posts: 13,141	Re: ezgo sputtering NO! That would be a direct short.. Run a jumper from the one large solenoid lug to the other large lug. This will act like closing the solenoid.

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