2018 EZGO Carbureted Kawasaki Wiring

[BurlyDeer]

Need some wiring help. Rodents wrecked my wiring. Any idea where this small blue wire terminates. It splices to blue from the pedal microswitch’s red wire (first pic) then runs along the main harness towards the battery (second pic) and connects to…I have no idea. I’d appreciate any input. Thanks.

 

[BeerToss]

I see what is going on now.... I do believe that this blue wire should connect to your control side on the solenoid. If you look at your solenoid the small terminals, one side should go to ground and the other side should have a power input from the pedal micro. When you actuate the pedal micro that will send power through the control side of the solenoid, this in turn completes the circuit back to your starter generator. If you could post a picture of the solenoid, we could verify that this is where the blue wire should go. The solenoid should be under a square like tp cover in the front left engine compartment by the battery.

 

[BurlyDeer]

I'll post some pics of the solenoid on here as well as the micro connections and wiring later today so that we can collaborate/verify. As always, appreciate the help brother.

 

[BurlyDeer]

Behold! The MAZE! Light blue wire was connected to old key switch and comes out by solenoid but is connected to nothing. Orange wire on the solenoid runs to dash and is connected to nothing. Dark blue wire is still connected to nothing and as discussed runs from the pedal micro’s red wire.

Concerning the dash area, the brown constant hot wire ran through a USB module (which I don’t care about) the yellow wire came out of the other side of the USB module and then piggybacked to the light blue wire on the keyswitch. The light green wire was also connected to the keyswitch opposite the blue and yellow.

Lots of problems

 

[BurlyDeer]

Upon closer inspection, the orange wire connected to the solenoid is a factory splice into the green pedalswitch wire...as in the green pedalswitch wire terminates into the orange. The orange then connects to the solenoid and continues up to the dash and connects with nothing currently.

 

[BeerToss]

Yeah, sounds like someone has been in there and done some finagling. That orange wire that goes to nothing in the dash was your oem key switch power, someone has installed that brown wire directly from the battery is what has happened. Really the key switch should be wired (orange wire) from the solenoid positive post, same post that the main battery goes too. When you turn on the key it will send power down to the pedal switch. When the pedal switch is actuated, it will send power to the control side of the solenoid. There really should be a micro switch on the directional control that the pedal switch would run to first.... before the solenoid. But all this does is trigger the reverse buzzer. It is a very common thing where people will just eliminate the reverse buzzer micro switch circuit to get rid of the reverse buzzer. So, when that happens the pedal switch output just goes directly to the control side of the solenoid.

 

[BeerToss]

I would really consider just rewiring that whole circuit (pedal/key switch) just so you know it is correct and that there are not any breaks in the system. I pretty regularly run into carts where that circuit has been shorted to ground somewhere, causing the fuse to blow in that circuit. Which usually results in someone finagling like has been done.

 

[BeerToss]

 

[BeerToss]

I maybe off on the colors of the wires just an fyi, but the wiring flow is correct lol

 

[BurlyDeer]

Well the theory that you provided certainly helps. If I can get the keyswitch powered then I feel like I can troubleshoot the rest of the circuit with a multimeter and some beers. I'm still not grasping how the keyswitch (or this entire circuit) is powered. I understand your theory of operation for what each switch should do after it is powered in relation to the other switches. I just need to grasp exactly how to power the circuit so that it isn't constantly hot (like they appeared to have wired it) while still powering the solenoid. I'll have to study that photo, I haven't seen that exact diagram that you posted and it most closely resembles my model. My intent is to do as you have suggested and rewire the circuit. Just need to figure out how to correctly power the circuit.

 

[BurlyDeer]

The buzzer circuit is intact and operational though! Yay! lol

 

[BurlyDeer]

Solved. This dark blue wire connects to the light blue wire that runs to the keyswitch. Thanks for the help! We're up and running!