2002 Electric Club Car DS (36-volt) Solenoid pre-charge resistor overheating

[Jayh21012]

Hello everyone, we use our 36 volt 2002 club car to tow small aircraft around the airfield. One day it stopped moving all together. I have no doubt this is because of how we use it. After rigorous research and troubleshooting I found there was some current draw which drained the batteries down to about 2 volts. I trickle-charged them all back up to about 6.2 volts per battery. I lost the keys so I put in a simple toggle switch. I rewired the entire activation circuit, replaced solenoid, replaced ms on f/r assembly, replaced ms on pedal drive assembly. Tested motor terminals for shorts to ground; good there. I have the cart drive-able now but the precharge resistor across the two large solenoid posts heats up beginning to melt the plastic covering when the pedal is only pressed a bit. So before it fried the resistor I pulled it out, tested it again just to be sure it works. I want to find out why there is current being pulled through it when it should all be going through the solenoid. Any insight is helpful, thanks.