ex1 engine electrical problems

[benthere]

ive got a 2021 ezgo valor with that ex1 fuel injected engine. I have no power at switch

[golfcartg]

If the ignition switch in your EZGO Valor follows the wiring pattern of earlier models you might encounter limitations. In such cases, power typically flows through the gas pedal switch before reaching the ignition switch. When the pedal is pressed down, it completes the circuit within the pedal switch, allowing power to flow from the battery to the ignition switch. This setup is designed to prevent accidental or unauthorized activation of the ignition system, enhancing safety and security by integrating the pedal switch into the power supply circuit. While this configuration may present limitations for certain accessory installations, it serves to enhance the overall safety and reliability of the carts electrical system.

If you happen to have a 3 position key switch fitted, like those often found in Workhorse models, there's a workaround. By using position 3 exclusively for accessories, you can effectively bypass this limitation. Just remember to turn off the key when parking to avoid draining the battery. This setup prevents your accessories, such as a radio, from cutting out whenever you release the gas pedal. Let me know if this answers your question or if you need further assistance feel free to ask!

[benthere]

If the ignition switch in your EZGO Valor follows the wiring pattern of earlier models you might encounter limitations. In such cases, power typically flows through the gas pedal switch before reaching the ignition switch. When the pedal is pressed down, it completes the circuit within the pedal switch, allowing power to flow from the battery to the ignition switch. This setup is designed to prevent accidental or unauthorized activation of the ignition system, enhancing safety and security by integrating the pedal switch into the power supply circuit. While this configuration may present limitations for certain accessory installations, it serves to enhance the overall safety and reliability of the carts electrical system.

If you happen to have a 3 position key switch fitted, like those often found in Workhorse models, there's a workaround. By using position 3 exclusively for accessories, you can effectively bypass this limitation. Just remember to turn off the key when parking to avoid draining the battery. This setup prevents your accessories, such as a radio, from cutting out whenever you release the gas pedal. Let me know if this answers your question or if you need further assistance feel free to ask!

all wires at ignition are dead

[golfcartg]

So in this situation we're dealing with a pretty common headache in these carts. The ECU and ISG act as the brain of the engine management system, receiving input from various sensors and controls to regulate fuel injection, ignition, and other critical engine functions. However, when one malfunctions, as indicated by the lack of power or failure of the cart to wake up, it can lead to significant operational issues like you're currently experiencing. Now here's the kicker, its common for any of these to decide to call it quits, and when they do, it's trouble.

One big issue were seeing is the placements of the computers themself. Ones tucked away in a spot where it can get real hot, and the other right above the motor (heat rises). When that happens, they can overheat and, well, kick the bucket. So even though it's doing its job fine and dandy, that extra heat and vibration can cause it to go. And when one decides to quit, it's like the whole cart just shuts down. No power to the starting relay, fuel pump, nada. To make matters worse, getting your hands on replacements ain't no walk in the park, they're in high demand and short supply, leaving folks waiting in line just to get their carts back up and running. Perhaps with you providing a bit of backstory we can piece together the puzzle.

[benthere]

sounds like i got a lemon, i bought this thing new so i wouldnt have problems, i bet this car dont have 50 hrs on it. but waranty is up

[golfcartg]

That's frustrating especially since you bought this brand new to avoid exactly these kinds of issues. Skip the dealership hassle and go straight to the source by reaching out to EZGO directly. Head to www.ezgo.com and scroll down to the bottom of the page where you'll find contact options via email and phone. You can also reach out to them on their social media platforms like Facebook or Twitter, which are also listed on their website. Filing a claim and getting in touch with a representative can help expedite the process and potentially lead to a faster resolution.

Given the nature of the issue, it's possible that this could be recalled and covered at some point, so it's important to keep the lines of communication open with EZGO. Remember to keep us in the loop. Sharing your experience can provide valuable insight for people searching the web facing similar challenges, so please keep us updated on your progress.

In the meantime, since replacements are scarce and if you can't afford to wait for a solution or need your rig up and running ASAP, consider reaching out to a computer rebuilder. Heat related issues with computers are common in cars and automobiles, and there are plenty of rebuilders on platforms like eBay that deal with fixing all sorts of computers daily. Sort search results by distance and check for local rebuilders who you could maybe drive to and have them take a look at your computer and see if it's rebuildable. Here is an example for that type of search

[benthere]

well started messin with this thing today, turn the ignition on pulled 10 amp fuse out then plug it back in, the one by the batterie, now all is good again
ill see how long it last but so far so good, maybe this little info could help someone else, thanks for the input.

[Michael Eddie]

Thank you for the update. Also thanks to golfcartg for sharing your wisdom.

Pulling out the 10 amp fuse is akin to hitting the electrical reset button. By doing so, you're cutting off power to components like the ignition and fuel injection system. It's like giving the carts electrical system a breather, clearing out any glitches or snags that may have cropped up. This quick fix can often resolve issues like electrical quirks or engine performance hiccups when in a pinch. Besides pulling the fuse, another way to achieve the same result is by disconnecting the battery. By disconnecting the battery terminals (starting with the negative terminal to avoid electrical mishaps), you effectively cut off power to the carts electrical system. Just remember, it might only be a temporary solution, and deeper troubleshooting may be necessary.

To troubleshoot whether the issue lies specifically within the ISG or ECU, instead of immediately resorting to pulling the fuse, consider a more targeted approach. If the problem occurs again, begin by disconnecting the plug(s) on the ISG or ECU and wait for 15 seconds before reconnecting it. If the issue persists, repeat the same procedure with the other. If the problem resolves after disconnecting and reconnecting either the ISG or ECU, it indicates that particular item may be faulty and in need of replacement. I'm including the wiring diagram here for those who could use it: Ezgo Valor EX1 TXT EFI 19, 20, 21, 22, 23, 24 (Gas) Wiring Diagram

[jsjohnson2024@aol.com]

well started messin with this thing today, turn the ignition on pulled 10 amp fuse out then plug it back in, the one by the batterie, now all is good again
ill see how long it last but so far so good, maybe this little info could help someone else, thanks for the input.

Where is the 10 amp fuse located

[Michael Eddie]

Where is the 10 amp fuse located

Inline the positive cable near the battery, its visible in the wiring diagram highlighted below:

[Michael Eddie]

As of 6/2/24, unconfirmed sources indicate that EZGO.com continues to accept warranty claims for the ISG controller, despite the golf carts being out of warranty.

To try for yourself, reach out to EZGO directly via their website providing them with information about your cart, including the number of approximate hours the cart has, especially if it’s under 100 hours.

• Typically, they acknowledge that this is a frequent issue potentially caused by a faulty batch of ISG controllers.
• Following that, you should take your cart to a local authorized dealer who will carry out the necessary repairs and file a warranty claim.
• Should the claim be denied due to the expired warranty status, refer back to your initial conversation with the EZGO manufacturer representative and request that the dealer resubmit the claim. This should help secure coverage under warranty.
• Anyone with experience in this warranty matter please report back, your feedback could be a valuable source of information for others searching the web facing similar issues.

[benthere]

well i just replaced mine for the tune of 415, i guess i can send the reciept an failed isg controller, it was the fix though.

[sosheetz@gmail.com]

New member here....

Sounds like I am having the same problems on my 2022 Gas Valor (bought new in Feb 2022) but let me see I have anything different. Worked fine yesterday morning, I parked for an hour while I ran to fill up gas tanks for the boat. When I jumped in to haul the gas down to our dock, NADA.

Checked all the fuses, even put a new battery in it to be sure. About a third of the time I can get the key switch to turn on which includes hearing the fuel pump turn on, the gas gauge and trouble light flashes and there is a soft click from the solenoid. If I turn the switch all the way, headlights also do turn on. I soon as I tap the gas pedal, everything cuts off including hearing another soft click from the solenoid (that is labeled D421, 12VDC 50A, correct?).

Is there something else I may be missing? Can I discern the difference between an ECU problem and the ISG?

Thanks, Steve

[golfcartg]

Hey Steve, welcome! From what you're describing, it sounds like the ISG controller might be the issue. When these carts first came out, there was some confusion due to limited information, but over time we've learned that the ISG controller is usually the problem area rather than the ECU. Its placement right above the engine and CVT belt subjects it to a lot of heat, especially in warm weather and when there's friction heat from the CVT belt going uphills. The earlier ISG controllers seemed to have been from a faulty batch, which didn't help matters.

To avoid frequent replacements, I'm thinking installing a heat shield between the engine and the ISG controller or relocating it to a cooler area could be beneficial. More info on that here in post number 6. Also, here is another thread that goes into more detail about troubleshooting other areas besides the ISG controller, just to be thorough. This should help you cover all bases and hopefully get your cart running smoothly again. Feel free to keep us in the loop!

[sosheetz@gmail.com]

Thanks for your input. It was the ISG as everyone seems to be having problems. I was able to get a replacement module at Mr. Golf Cart in Waynesboro GA - current price is $250 plus tax. The parts guy wasn't surprised - says it is a real problem - says this is like version 5 so maybe it will last longer. Cheaper than others have found but still money that shouldn't need to be spent on a cart that was bought new and lightly used at our lake house. He's going to see if he can get some help from EZ Go. Any knowledge of a class action lawsuit for getting these replaced and/or redesigned? Thanks.

[Michael Eddie]

Thanks for your input. It was the ISG as everyone seems to be having problems. I was able to get a replacement module at Mr. Golf Cart in Waynesboro GA - current price is $250 plus tax. The parts guy wasn't surprised - says it is a real problem - says this is like version 5 so maybe it will last longer. Cheaper than others have found but still money that shouldn't need to be spent on a cart that was bought new and lightly used at our lake house. He's going to see if he can get some help from EZ Go. Any knowledge of a class action lawsuit for getting these replaced and/or redesigned? Thanks.

Given the recurring issues with the ISG controller, the idea of a class action lawsuit is understandable. However, I would like to politely ask everyone to exercise some restraint in this situation. As far as we know, no one has been hurt due to this issue, and escalating to a lawsuit could defeat the purpose of this forum as a constructive discussion point for fans and users of this beloved brand. We've covered this topic extensively, and it's now well documented on various internet searches.

Furthermore, from our last check, EZGO has been quite responsive in honoring warranties on the ISG controller, even for carts that are technically out of warranty, particularly if they have low usage hours. This indicates that they are aware of the problem and are willing to support their customers. I would strongly recommend contacting EZGO.com directly before considering any legal action. They might be able to offer a resolution without the need for further escalation.

I also want to thank you for sharing your experience with getting a replacement module from Mr. Golf Cart in Waynesboro, GA. It's great to hear that you found it for $250 plus tax, which is indeed the lowest price I've seen so far. Your report on this fix is invaluable, and I'm sure others will benefit from knowing this source. Please do reach out to EZGO and report back with your results so we can continue to support one another in this forum.

[Michael Eddie]

As of 8/23/2024 we’re thrilled to share that the price of the ISG controller has dropped to $150 on www.shopezgo.com, a significant reduction from the previous $450 or more. What’s even more impressive is that EZGO is selling these at a loss to make them more affordable for all of us. This isn’t just a random discount, it’s a direct result of the community coming together and pushing for a better fix. It’s fantastic to see EZGO stepping up and honoring this commitment. Thanks for making it easier for everyone to keep their carts on the road.

If you're just catching up on this and think your faulty ISG controller should be covered under warranty, even if your cart is out of warranty and especially if your cart has low usage hours, be sure to check post #11 for more details on that.