91 ezgo solenoid smoking

[Carlharr]

I got a 91 ezgo. I replaced all the wires, key switch, and fwd/rev switch. Got the batteries to charge. All are at 5.7 and 6 volts. When I turn the key on sounds like a humming coming from the solenoid. I pressed the pedal and the solenoid started smoking. Is there anyone out there may know what happened. I checked all the wires and they are where they need to be.

[Sideways]

Post some pictures.
Regarding your batteries, see the chart below.

[Carlharr]

Ok thanks any idea why my solenoid is smoking?

[JohnnieB]

Your battery pack is less than 50% charged and drive systems have to draw more amps to do the same work when the batteries are low. More amps means more heat.

The stock solenoid is only rated at about 85A and while the contacts will pass a couple hundred amps momentarily, passing higher than the rated amps for prolonged periods of time will over heat the solenoid.

Fully charge your batteries and keep them charged as much as possible.

Also, I solenoid with a higher amp rating would be a good idea, the contacts in your solenoid are most likely damaged.

[Carlharr]

Ok thanks. I have a new one on the way. Should be here monday. I will let you know if that works.

[Carlharr]

I finally got the new solenoid in. And found out that I had the diode in backwards. And that was what was smoking not the solenoid. I put in a new diode in the right Direction and the cart came to life. Works good now.