series cart only runs with jump wire on solenoid

[Tamster]

I bought a 2004 EZGO TXT series cart that had a jump wire from the solenoid to the first positive battery terminal on the pack. The guy I bought it from said the solenoid was bad, so after replacing the solenoid it still did not work with out the jump wire. The cart has worked intermittently without the wire on occasion. So I replaced the key switch thinking that was the issue. Still a no go.. One weird thing it will do is every so often I will try moving the key switch and the cart will move forward about 2 feet or so then come to a slow stop and not move again. My guess is there is a wire shorting somewhere, but any help would be appreciated. One thing I am wondering is if the controller is bad will the cart work with a jump wire? Thank you for any help on this situation.

[yurtle]

I melted the guts on two stock solenoids, so it's possible the same happened to yours. The contact is round and can rotate, making connections intermittent, even though it clicks.

Is your jumper a small wire or a large cable?

[Tamster]

Is there any way to tell if that's happened or do I just need to buy a new one? The solenoid does click every time the peddle is depressed, with or without the jump wire.

[yurtle]

If the jumper wire is a large cable, you can disconnect each side and do a continuity test. OR you can see if you have voltage going to the motor. It would be helpful to know what buggy you have.

Owner's, Parts, and Service Manuals:
http://www.buggiesgonewild.com/elect...g-manuals.html

Wiring Diagrams
http://www.buggiesgonewild.com/elect...-diagrams.html

http://www.buggiesgonewild.com/elect...g-manuals.html

Dana Axle:
http://www.buggiesgonewild.com/attac...5-28148g01.pdf

Golf Cart Serial Number Lookup:
http://www.shopezgo.com/customer-ser...ialNumber.html

Controller/Motor Type:
http://www.buggiesgonewild.com/attac...go-guide-2.jpg

http://www.buggiesgonewild.com/elect...en-system.html

[Tamster]

Its a 2004 EZGO TXT series cart.

[Tamster]

Its a 4 gage wire.

[scottyb]

If i'm reading this right the solenoid does not click when you try to go and the cart doesn't move?
If that is the case and you now have a new solenoid that does not click either then the trouble may be in the go pedal micro switch ...... under the floor board.

[Tamster]

The solenoid does click when you push the peddle and the micro switch has been checked it appears to be working.

[Tamster]

I may not have made myself clear in my original post. The cart does move and run fine with the Jumper wire installed. The solenoid does click when the peddle is depressed with the jumper wire installed. The key switch does not need to be on when the wire is installed. When the wire is NOT installed the key switch ON the solenoid does click but the cart does not move. If I am reading past post and diagnosis correctly it sounds as if there is a bad switch somewhere. I hope this helps a bit more on trying to diagnose my problem.

[mgray70]

Which side of that solenoid is the jumper attached to? If it is the battery side, I would suspect the cable from the battery to the solenoid. If it is on the controller side, I would suspect the new solenoid. If the solenoid clicks either way your activation circuit sounds like is working fine.