Ezgo Marathon has me puzzled.

[LukeL]

I’m working on a very clean 1991 Marathon for a guy in town. He said he was driving it up a small hill and it quit on him. So I went over and replaced the solenoid. Nope.

So I started testing the solenoid activation circuit, and lo and behold the microswitch on the FNR was bad. So I replaced it with a brand new one and I tried driving it. I got about ten feet and the microswitch burned out. The new one. Key switch is good, POT microswitch is good.

For some reason I feel the controller is trying to get its power from the solenoid activation circuit rather than the B+?

As soon as I put the FNR in forward or reverse, the solenoid clicks and stays held until I move it into neutral. Regardless of pedal position or key switch position.

What should I do next? Controller issue?


Club Car DS driver’s club #59

[nickdalzell1]

Is there a diode in between the small solenoid terminals? On these if it's missing or bad you'll blow microswitches for the accelerator pretty fast.

[LukeL]

There is a diode and I replaced it with the new solenoid (another used one but it was good.)


Club Car DS driver’s club #59

[BobBoyce]

If the diode is installed backwards, it will blow microswitches, and possibly short out the diode as well, continuing to cause microswitches to blow.

[Mooncarter]

Originally Posted by BobBoyce

If the diode is installed backwards, it will blow microswitches, and possibly short out the diode as well, continuing to cause microswitches to blow.

[LukeL]

I’m pretty sure it’s right because I’ve done several, but I’ll check it. I’ll let you guys know.

Thank you!


Club Car DS driver’s club #59

[LukeL]

I checked the diode and I have it right (the line is on the positive side).

I bypassed the microswitch I just replaced on FNR, and as soon as I try to run the cart, the wire going to the keyswitch bursts into smoke. For some reason this controller is trying to take its voltage from the activation circuit.


Club Car DS driver’s club #59

[LukeL]

I think I may have figured it out now – someone added a micro switch and solenoid to jump a couple of the posts on the motor to make it faster. I got rid of all that junk and it may be working normally now. I’ll let you guys know.


Club Car DS driver’s club #59

[orangeman6]

Originally Posted by LukeL

I think I may have figured it out now – someone added a micro switch and solenoid to jump a couple of the posts on the motor to make it faster. I got rid of all that junk and it may be working normally now. I’ll let you guys know.


Club Car DS driver’s club #59

Just curious and always trying to learn, how did that make the cart faster?

[kernal]

Originally Posted by orangeman6

Just curious and always trying to learn, how did that make the cart faster?

Probably some sort of "field weakening" AKA field shorting set up. Google it. Can lead to some entertaining reading. Has beed discussed at length on the forum in the past. Best I can recall it was in the extreme DC section.