New Solenoid, Blowing Fuse

[yurtle]

Gotcha. I'm jumping into the middle of something, and don't know the whole background.

Not knowing everything ScottyB does, I would have told you to eliminate the four wire Molex connector, seen in one of you photos, between the throttle box and the wiring harness. I soldered mine, but butt-splices will work. Cover with marine grade heat-shrink.

It's possible your diode may be shorted? Did you install it with the band to the positive side, the red wire(s)? Should be the same orientation as you old one. If that's not it, you may just have a shorted coil. Probably very uncommon, but possible.

If you don't have one, borrow or buy a handheld multimeter that measure volts to 2 decimal places and does ohms and continuity. Should be $20 +/- at Home Depot, Ace, Lowes, Walmart, Autozone, West Marine, etc. Test solenoid coil without diode. Test diode in both directions. Report back.

[yurtle]

Originally Posted by Jhertel07

Installed new solenoid, diode, resistor just like old one. Solenoid doesnt even click, just blows the fuse

Make sure the diode is in the same direction as the old one.

Knowing this, it would be a waste of fuses to continue to try this without testing the new solenoid as mentioned above.

[Jhertel07]

I'll test diode. Quick question... what part of the solenoid would have juice with the key off? I just got zapped when my hand hit while trying to checkthe 4 wire run/ molex connector

[yurtle]

Do you know what controller you have? Can you post a pic? Given the solenoid, I'm guessing it's an AXE, an SR, or maybe something in between as far as years. That will help me give you the correct wiring diagram. There's more than one way to wire these, AND the SR controllers feed the solenoid pack negative, something the stock and AXE controllers didn't.

[Jhertel07]

It's an alltrax 500 amp. Model spm48500ez

[yurtle]

I'll post it, in case you don't have it. I've never looked at those before. As to your question, I get zapped all the time, when I touch positive or negative. I'm always barefooted.

https://alltraxinc.com/

Legacy Products

https://alltraxinc.com/spm-products/

https://alltraxinc.com/wp-content/up...T-WIRE-DIA.pdf

So this is the same as the SR. Solenoid gets pack negative from the controller. This allows the controller to prevent the solenoid from activating if it's pissed off, unlike the stock or AXE.

[Jhertel07]

Bad diode! The new diode was full continuaty. Glad i had the fuse in place

[Jhertel07]

I put the old diode on (had to lengthen it) and everything is working now. Very grateful for your help!

[yurtle]

YAY!

I've never seen a shorted diode. I always manage to blow them to bits. Not in a cart.

I'd still eliminate the Molex connector. Mine went intermittent, and would fail several times a year until I replaced it.

If humidity still seems to cause problems, I'd look inside the throttle box. See if you can seal it better. Mine went under water several times in one evening, and only got a few drops inside, which is batter than I expected.

[Jhertel07]

That's good advice, will do. Appreciate it!