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Electric EZGO Electric EZ GO Marathon, Medalist, TXT and RXV. |
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07-06-2018, 02:27 PM | #1 |
Not Yet Wild
Join Date: Oct 2016
Location: Ham Lake, MN
Posts: 8
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'99 TXT electric wires melting
Hey everyone,
My 99 TXT, series cart has an issue and I've melted a post, obviously, this is wired wrong. I disconnected a 12v headlight accessory wired to other posts so not really involved with this. The white wire coming out of the recharge receptacle coverts to red through the harness and ties into the main positive terminal. The issues, 1. where should this wire go to and 2, should I add a 12-volt converter to add my 12-volt accessories to? Here are some pics. although I'm not sure why they are coming out upside down.....sorry. |
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07-06-2018, 03:47 PM | #2 |
Gone Wild
Join Date: Sep 2016
Location: Northern California
Posts: 1,300
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Re: '99 TXT electric wires melting
The wire out of the charge receptacle was for the reed switch, which is a safety device designed to keep you from driving away with the charger plugged in.
Melting terminals indicate too much resistance. Corrosion, loose terminals, etc. Yes, get a voltage reducer or a separate 12v battery to run your accessories. |
07-07-2018, 09:36 AM | #3 |
Gone Wild
Join Date: Jan 2014
Location: South Georgia
Posts: 1,120
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Re: '99 TXT electric wires melting
Poor choice of washer under the nut which probably caused problem. Not enough contact area.
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07-07-2018, 11:13 AM | #4 |
Gone Wild
Join Date: Sep 2016
Location: Northern California
Posts: 1,300
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Re: '99 TXT electric wires melting
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07-07-2018, 01:22 PM | #5 |
Gone Wild
Join Date: Jan 2014
Location: South Georgia
Posts: 1,120
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Re: '99 TXT electric wires melting
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07-07-2018, 02:07 PM | #6 |
Gone Wild
Join Date: Feb 2017
Location: Richmond, TX
Posts: 1,026
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Re: '99 TXT electric wires melting
Agree the accessory ring terminals are too big.
Clean it up and lube it all up with say PB blaster for a little while. Remove the nut and wires and clean the stud with wire brush. Cut off all terminals and replace then with the correct size hole terminals. 5/16" On the Pos cable the terminal needs replacing at least and maybe the whole cable. The corrosion may have crept into the cable and can't be used for new terminal. Always install the higher current cables lower so the large pos to the battery goes on first and then the rest. Install a new nut and tighten to 100 inch pounds. |
07-07-2018, 04:33 PM | #7 |
Not Yet Wild
Join Date: Oct 2016
Location: Ham Lake, MN
Posts: 8
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Re: '99 TXT electric wires melting
Thank you all for the replies. I tore apart the wire harness - there are two affected red wires, 1 from the white cable off the charger to the left side of the POS terminal and then the right one traced back to the right side of the solenoid. The second one was completely fried but I think the solenoid is fine. Now to decide if I should upgrade to 4 gauge for the new cables. What're your opinions?
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07-07-2018, 04:52 PM | #8 |
Gone Wild
Join Date: Sep 2017
Posts: 690
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Re: '99 TXT electric wires melting
Upgrading never hurts.
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07-08-2018, 07:24 AM | #9 |
Gone Wild
Join Date: Jan 2014
Location: South Georgia
Posts: 1,120
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Re: '99 TXT electric wires melting
Fix what is broke first and add a 12 volt reducer instead tapping batteries. Upgrading sometimes causes more problems. See post #6.
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