1996 GXT804D - Was Running, Now Nothing

[BurntClutch]

Hello All!

One of my first posts, so hopefully I can provide some good info, and forgive me if I dont know the right lingo...

Brought home a "Tuff1" today that was bought off of CL. Its a 1996 GXT804D according to shopezgo, and it came with a 4" lift and some bigger tires. Backed it off the trailer fine, and took it down the road with the family.

Had the lights turned on, and then when we tried to reverse it when we turned around, it just died. Nothing. No lights, doesnt even try to chug over.

The wiring is a nightmare, and lots of stuff has been jumped out, so not sure what might be wrong. The battery cable leading to the solenoid was pretty warm, and occasionally the starter/generator chugged, but not when I was doing anything.

So my guess is that something got overheated or died from the headlights running, and maybe its as simple as the battery is dead, but Im assuming there is more to it.

Any idea if any of the manuals that are posted here have the right info for my model? Any other items to check first?

Thanks in advance!

[yamahaguy97]

if the wiring was a nightmare, and the starter attempted to turn, i would say a bad or loose connection. check anywhere there is a fuse too to make sure. it is probably something simple im sure you will find it

your right, check the battery to be sure too

[BurntClutch]

Originally Posted by yamahaguy97

if the wiring was a nightmare, and the starter attempted to turn, i would say a bad or loose connection. check anywhere there is a fuse too to make sure. it is probably something simple im sure you will find it

your right, check the battery to be sure too

Thanks for the quick reply!

It ran great around the yard, just seemed to not like the road vibrations. Ill put it on the charger tomorrow to see if thats it, but will be hunting a wiring diagram to see if I can help trace things out. Looks like there used to be a fuse box, but thats abandoned. The horn doesnt work, backup alarm wires are cut, etc. So not quite sure what is supposed to be there and what is broken yet....

[BurntClutch]

Turns out its the simple things to check first... Battery was dead as a stick. Put it on the charger and we had liftoff. I think some of the connections are pretty lousy, so it needs to have more juice than it did. Plus I had the lights switched on, and I guess that was enough extra draw to do me in, and I couldnt get things to kick back over.

So, charged up for now, and Ill start re-wiring once I can get a good diagram.

[yamahaguy97]

Good idea, and once you do every connection will be proper and secure

Yep, battery is most important. Without battery carts are just huge paperweights lol

[BurntClutch]

Aaaaaaand I spoke too soon.

After charging, cart died again the next day. Took several hours on the auto charger, then was dead as a stick. Right now my key switch is jumped out (replacement on order), so I thought I was draining down that way. Even with the jumper disconnected, it still died on my wife today after an hour of her running around the yard doing some chores.

I guess its time to get the battery tested first, and then get to the wiring job. It looks like someone has purchased a new wiring harness and put that in, but didnt remove the original one. I guess the wiring diagram in the service manual will be a pretty helpful thing...

[meimk]

See if it's charging. Once you've got it charged where it will start, compare battery voltage "at rest" with voltage while running.

[abgiles]

Originally Posted by BurntClutch

Aaaaaaand I spoke too soon.

After charging, cart died again the next day. Took several hours on the auto charger, then was dead as a stick. Right now my key switch is jumped out (replacement on order), so I thought I was draining down that way. Even with the jumper disconnected, it still died on my wife today after an hour of her running around the yard doing some chores.

I guess its time to get the battery tested first, and then get to the wiring job. It looks like someone has purchased a new wiring harness and put that in, but didnt remove the original one. I guess the wiring diagram in the service manual will be a pretty helpful thing...

Where'd you find the service manual? New here myself, and have some similar looking wiring.

[BurntClutch]

Originally Posted by abgiles

Where'd you find the service manual? New here myself, and have some similar looking wiring.

There was a used one on eBay that I hope is the right one for my cart. But I have found some other diagrams by doing a google image search that look like they would get me in the ballpark....

[cart around]

Originally Posted by abgiles

Where'd you find the service manual? New here myself, and have some similar looking wiring.

Try looking through these.
http://www.buggiesgonewild.com/ezgo-...iagram-id.html