Tow/Run switch has to be toggled all the time to continue driving

[dalepmay]

I have a 2008 Yamaha YDRE, bought used about a year ago, I know nothing about it's past maintenance. At random times while driving, almost always while accelerating from a stop, there will be a click, and everything stops working. I have to toggle the switch to Tow, then back to Run, in order to make it work again. I replaced the switch thinking it was the issue, and it still does it with the brand new one. I even bypassed the switch with a straight wire and had to then disconnect and reconnect that wire to continue operation. Any idea what I need to check to troubleshoot? I know nothing about these, so any help would be greatly appreciated. Thanks guys!

[Volt_Ampere]

I'm afraid that the most likely cause is a problem with the controller. Not much else that it could be.

[Ryokuro]

Are those the Moric controllers on those things? They're not great in my opinion. Sounds like it's time for an upgrade to an Alltrax or Navitas...

[dalepmay]

Originally Posted by Volt_Ampere

I'm afraid that the most likely cause is a problem with the controller. Not much else that it could be.

That's what I was afraid of. I've looked up a couple online, and not thrilled about the cost, but it is what it is. What are some good models I should consider?

[Volt_Ampere]

If you go for a new controller, I would go with Alltrax - either the 400Amp or 500Amp. I have two of them and they are way better than the stock Moric controller. You can program it for what ever speed you want and lots of other stuff. It's a drop in replacement. The 500 Amp one has a cooling fan. You need to order the correct model for your YDRE cart - so that you get the right plug connection. The stock Moric controllers are fairly prone to failure - although I have not heard of the failure mode you are seeing.

[dalepmay]

Originally Posted by Volt_Ampere

If you go for a new controller, I would go with Alltrax - either the 400Amp or 500Amp. I have two of them and they are way better than the stock Moric controller. You can program it for what ever speed you want and lots of other stuff. It's a drop in replacement. The 500 Amp one has a cooling fan. You need to order the correct model for your YDRE cart - so that you get the right plug connection. The stock Moric controllers are fairly prone to failure - although I have not heard of the failure mode you are seeing.

Thanks for the info!

[camaroluvz28]

Wait this is what happens when a Yamaha has a weak or bad battery also I wouldn't just go get a controller...what year are your batteries? If the pack voltage drops under hard acceleration the controller will throw a fault until reset (flipping run/tow) switch...

[Volt_Ampere]

Originally Posted by camaroluvz28

Wait this is what happens when a Yamaha has a weak or bad battery also I wouldn't just go get a controller...what year are your batteries? If the pack voltage drops under hard acceleration the controller will throw a fault until reset (flipping run/tow) switch...

Good point. I would check batteries AND connections between them before declaring the controller bad.

[dalepmay]

Originally Posted by camaroluvz28

Wait this is what happens when a Yamaha has a weak or bad battery also I wouldn't just go get a controller...what year are your batteries? If the pack voltage drops under hard acceleration the controller will throw a fault until reset (flipping run/tow) switch...

That's interesting. The batteries I know are pretty old, but they seem to still hold a charge and work fine as far as I can tell. I put a 48v battery meter in and it all looks good. The easiest way to reproduce the issue is when the parking brake is on, and I tap the gas to release it, if I don't continue moving at the same time, and just tap it to release and immediately let off, about 50% of the time it will trip, and I have to cycle the switch to continue. It does it when the break releases and the cart rolls slightly without acceleration. This makes me think it's something with the roll-away system/sensor, but I don't have any prior experience with these, so I'm kind of just making assumptions.

Side note/question, has anyone put a single Lithium Ion battery in one of these? I've seen the Roypow 51V battery in a neighbor's cart, but those things are pricey.

[dalepmay]

Originally Posted by Volt_Ampere

Good point. I would check batteries AND connections between them before declaring the controller bad.

Now that I think about it.....when I first got the cart (last September) it did this a lot, then I topped off the water in the batteries (it has an easy fill system installed thank god!). After filling them it stopped doing it for a number of months. Now it started again, and I'm in Texas, where the temps in the garage got to near zero not too long ago, and I haven't checked the batteries' water level. This might be an easier fix than I thought!