Ezgo electrical problem

[busa64]

Just put a lift kit and tires on my 2007 ezgo pds cart and the solenoid is getting hot and the wires coming from positive side of battery to solenoid with red wire to controller is getting hot. Any help would be greatly appreciated

[JohnnieB]

What is the tire height?

With taller tires, the motor is drawing more current, so the original weaknesses in the system are now more pronounced.

Any heat in any cable, connection or component means there is excessive resistance in it.

Replace all 10 high current cables with 4Ga or larger high strand count welding cable.
Replace the solenoid with one that has a 200A continuous or greater rating.
Plan on replacing controller with one that has a 400A or greater rating.
Clean and tighten all connections. DO NOT overt-tighten battery connections, torque to 95 to 105 Inch/Pounds.

[busa64]

OK thanks ill start on cables and looking for a solenoid

[scottyb]

You need a 200 amp solenoid minimum.

[busa64]

With a stock cart?

[JohnnieB]

The moment the cart was lifted and taller tires installed, it ceased being stock.

[scottyb]

Originally Posted by JohnnieB

The moment the cart was lifted and taller tires installed, it ceased being stock.

Exactly.
I hear this often. In fact the moment the carts use changes from the game of golf it ceases being a stock cart, really. Because stock carts run 275 yards on groomed trails and rest for 10 minutes. And repeat.
I have seen many stock carts burn up solenoids and controllers because they are driven continuously and/or on steep terrain.
Hope this helps.

[JohnnieB]

Originally Posted by scottyb

Exactly.
I hear this often. In fact the moment the carts use changes from the game of golf it ceases being a stock cart, really. Because stock carts run 275 yards on groomed trails and rest for 10 minutes. And repeat.
I have seen many stock carts burn up solenoids and controllers because they are driven continuously and/or on steep terrain.
Hope this helps.

I hadn't thought of it that way, but you are right, if the application is no longer "Stock" the cart has to be upgraded to the application.

I learn new stuff every day.

[scottyb]

Originally Posted by JohnnieB

I hadn't thought of it that way, but you are right, if the application is no longer "Stock" the cart has to be upgraded to the application.

I learn new stuff every day.

It is not uncommon to see stock carts burn up stock components in what some would consider moderately modified use.
Another common belief is that the cart can remain stock if it is used for golf all year and just pulls the boat out of the water once a year or pulls a float in the Christmas parade ...
The cart needs to be built for the toughest duty it will do. So if once a year it's used to get to the top of the mountain, it needs to be built to that task regardless of what lesser tasks it does the rest of the year.
I hope this helps.

[JohnnieB]

Along the same line, another factor to consider is that every component in the cart has the least wherewithal needed to last the warranty period. If a component has more capabilities than what is absolutely needed, a lesser component isn't available or costs more.

In other words, if anything fails, replace it with better.