Club Car won't run with fully charged batteries

[jeff0181]

Originally Posted by Waco

After just going through something similar Here are my first questions. Did you buy the golf cart in not running condition? Did the cart ever run for you? I found my problem was a loose connection on the motor. There are a lot of wiring connections on the controller. If you don't know what kind of care the cart has had. Maybe it set outside a lot and connections just get bad. I cleaned all of them I could find. I don't really know how to check the controller or the motor. Maybe someone else here can help with that. But I learned how to clean connections. LOL. I think you have to start with cables and wires because it is a cheap fix.

I bought the good cart in running condition. The batteries it came with lasted a year and then I replaced them. The bottom of the cart is fairly rusted from the salt in the air on the South Carolina coast.

[jeff0181]

Originally Posted by jjance

I'm thinking your solenoid in not pulling in. Try this. Jack the rear wheels off the ground.(safety). On the solenoid there two large wires one on each large post. One post has a small wire. Remove the large wire from the post that doesn't have the small wire. Then connect it to the other large terminal. Disconnect battery when making connections. Or to make it easier jumper the two large solenoid terminals together with a large jumper like a battery jumper cable. Don't worry about the resistor. It's out of the circuit but put it back on after checking

I'll try it and let you know. Thanks.

[jeff0181]

Originally Posted by jjance

I'm thinking your solenoid in not pulling in. Try this. Jack the rear wheels off the ground.(safety). On the solenoid there two large wires one on each large post. One post has a small wire. Remove the large wire from the post that doesn't have the small wire. Then connect it to the other large terminal. Disconnect battery when making connections. Or to make it easier jumper the two large solenoid terminals together with a large jumper like a battery jumper cable. Don't worry about the resistor. It's out of the circuit but put it back on after checking

Just so I understand, once I connect the large wire from the post with no small wire and attach it to the other post I should reconnect the battery and then see if it works?

[jjance]

Correct. But do the safety items. Drive wheels off the ground put it up on blocks. It may want to take off. If the wheels start spinning fast shut it off with the key. But really you should have no problem doing this test. Some people leave it in this condition with a bad solenoid.

[jeff0181]

Originally Posted by jjance

Correct. But do the safety items. Drive wheels off the ground put it up on blocks. It may want to take off. If the wheels start spinning fast shut it off with the key. But really you should have no problem doing this test. Some people leave it in this condition with a bad solenoid.

Where is the solenoid located?

[jeff0181]

Never mind. Found the solenoid. There is already a bridge or small wire running between the 3 posts already. Should I just remove that?

[jjance]

If your talking about the precharge resistor you don't need to remove it.
Here is a picture of a solenoid. You want to remove the large wire on the left large terminal and connect it to the one on the right. Don't mess with the little wires.

[jeff0181]

Put the left wire on the right. Still exhibiting the same behavior in regards to no movement in FWD and temporary movement in REV.

[jeff0181]

Originally Posted by jjance

Correct. But do the safety items. Drive wheels off the ground put it up on blocks. It may want to take off. If the wheels start spinning fast shut it off with the key. But really you should have no problem doing this test. Some people leave it in this condition with a bad solenoid.

Removed some seat covers to get a better look. Switching the wires still didn't fix it, but with the pedal down, there are occasional visible sparks coming from the solenoid, mainly on the right side. Also, without the key on, occasional spark was observed. Solenoid itself as well as some sort of junction right below it is fairly dirty with rust.

[jjance]

The sparking is probably from a bad/loose connection. Or the rust may be causing a bad connection. Clean it up. It may not solve your problem but it needs to be done.