Simplify 1986 E-Z-GO Resistor to Solid-State Conversion

If you’re driving a 1986 E-Z-GO golf truck with the obsolete resistor regulator framework, you might be passing up critical upgrades in execution, proficiency, and well-being. Switching completely to a strong state regulator can decisively improve your truck’s power conveyance, broaden its life expectancy, and diminish the required support. In this aide, we’ll tell you the very best way to change over your E-Z-GO long-distance race from a resistor framework to an advanced, strong state regulator, guaranteeing smoother rides and better energy use.

Client Aim: Toward the finish of this article, you’ll have the information to without hesitation overhaul your E-Z-GO truck to a strong state regulator, making it a more solid and proficient vehicle for the long run.

Why Upgrade to a Solid-State Controller?

Changing over from a resistor regulator to a strong state regulator offers a few key advantages:

Further developed Execution: Strong state regulators give smooth and predictable power, which permits your golf truck to speed up more effectively, keep up with speed longer, and tackle slants with no sweat.

Energy Proficiency: Strong state frameworks consume less power, significance you’ll get more out of each and every charge contrasted with resistor frameworks, which squander energy as intensity.

Strength and Dependability: Strong state regulators have fewer moving parts than resistor-based frameworks, bringing about less mileage and a more extended by and large life expectancy.

Security: Resistor frameworks can overheat because of wasteful power dissemination, expanding the gamble of fire. Strong state regulators work cooler, which diminishes the possibility of overheating.

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Pre-Conversion Considerations

Before diving into the conversion process, there are a few important considerations to keep in mind:

Compatibility Check:

• Engine Similarity: Most engines in 1986 E-Z-GO trucks can deal with the move up to a strong state regulator, however, it’s fundamental to confirm that your current engine will work accurately with the new framework.
• Voltage Arrangement: Guarantee your truck is running on the right voltage (36V or 48V). The strong state regulator ought to be picked in light of the voltage of your framework for ideal execution.

Tools and Equipment Needed:

Here’s a list of essential tools and components required for the conversion:

• Devices: Screwdrivers, torques, multimeter, heat recoil tubing, and a wire stripper.
• Security Stuff: Consistently wear protected gloves and goggles to safeguard yourself while dealing with electrical parts.
• Parts: Strong state regulator, updated solenoid, potentiometer choke unit, rock solid wiring and connectors, and perhaps a redesigned battery pack.

Estimated Costs:

The costs of converting to a solid-state system vary depending on the quality of parts you choose:

• Solid-State Controller: $200 – $400.
• Upgraded Solenoid and Throttle: $50 – $150.
• Wiring and Miscellaneous Parts: $30 – $100.

Required Components for the Conversion

Now that we’ve covered the preparations, let’s look at the components you’ll need:

1. Solid-State Controller: A controller that matches your system’s voltage and motor type. Popular brands include Alltrax and Curtis, which offer reliable and high-performance options for E-Z-GO carts.
2. Upgraded Solenoid: Since resistor systems use solenoids to control current flow, you’ll need a solid-state compatible solenoid that can handle the higher current demands.
3. Throttle Conversion Kit: Resistor-based systems use a wiper board, while solid-state controllers use a potentiometer-based throttle system. This kit will convert your throttle from mechanical to electronic control.
4. Heavy-Duty Wiring and Connectors: Upgrading to a solid-state controller often requires thicker wires and high-quality connectors to handle the increased current flow.
5. Battery Setup: If you’re upgrading from a 36V to a 48V system, you may need to replace your battery pack as well.

Step-by-Step Conversion Process

Step 1: Preparation

1. Disconnect the Battery: Ensure that the battery is fully disconnected to avoid any electrical shocks during the process.
2. Remove the Old Resistor System: Disconnect the existing resistor system, including the wiper board. You can use a multimeter to ensure no current is flowing through the system before proceeding.

Installing the Solid-State Controller

1. Mount the Controller: Find a secure location for the new solid-state controller in the cart. The controller should be mounted away from excessive heat sources.
2. Connect to the Motor: Connect the controller to the motor using the provided wiring. Make sure all connections are tight and insulated properly to prevent electrical shorts.

Wiring and Connections

1. Wiring Diagram: Use the controller’s manual or a provided wiring diagram to ensure all connections are correctly made. For example, the positive and negative terminals from the battery pack need to connect to the correct inputs on the controller and solenoid.
2. Solenoid and Throttle: Install the upgraded solenoid, and connect the potentiometer throttle to the controller. Make sure the throttle operates smoothly when you push the pedal.

Throttle Installation

• Install the new potentiometer throttle, which involves connecting it to the controller. This allows for more precise and consistent speed control.

Testing and Calibration

1. Reconnect the Battery: With all components installed, reconnect the battery and ensure everything is wired correctly.
2. Initial Testing: Power on the system, and test the cart’s functionality at low speed first. Gradually increase the speed to verify smooth acceleration.
3. Calibration: If your controller has a programming interface, you can calibrate it to ensure it works optimally for your specific needs. If not, make sure the throttle and solenoid work as intended during the test run.

Maintenance and Troubleshooting Tips

• Regular Inspections: Check the wiring, solenoid, and controller for any signs of wear or loose connections.
• Battery Maintenance: Regularly charge and check the condition of your battery to ensure it’s operating at full capacity.
• Common Issues:
  • Controller Not Responding: Ensure all wires are securely connected and that the throttle is properly calibrated.
  • Overheating: If your controller is overheating, make sure it’s properly ventilated and not exposed to excessive heat.

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FAQs

Do I need to upgrade my motor when converting to a solid-state controller?
Not necessarily. Most motors in 1986 E-Z-GO carts are compatible with solid-state controllers. However, if you’re upgrading to a higher voltage (e.g., from 36V to 48V), ensure your motor can handle the increased power.

Can I perform the conversion myself, or should I hire a professional?
The conversion can be done as a DIY project if you’re comfortable with electrical systems and have the necessary tools and components. However, if you’re unfamiliar with wiring or motor mechanics, hiring a professional is recommended to ensure safety and proper installation.

How long does it take to complete the conversion?
The conversion process typically takes 4–6 hours for someone familiar with golf cart systems. Beginners may take longer, as the process involves carefully removing the resistor components, installing new parts, and testing the system.

Conclusion

Upgrading your 1986 E-Z-GO from a resistor controller to a solid-state system can breathe new life into your golf cart, enhancing both performance and efficiency. By following this detailed guide, you can confidently tackle the conversion yourself or with professional help, ensuring you get a smoother, more reliable ride for years to come.