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Unread 03-26-2015, 09:07 PM   #1
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Default 93 DS resistor cart clunking sound and hesitation

I have a 36 volt cart. The cart quit because the main negative wire to the motor, melted off the motor. probably was loose.

So i had the motor rebuilt locally. I installed the new motor, and went for a test drive. I notice when i step on the go pedal, the cart starts to move , and if i continue to step down on the pedal, the cart seems to " kick it up a notch", then takes off. I can hear a slight clunk sound as this happens.

So I installed a motor centering kit ( this is a aftermarket heavier motor.

The centering kit made no difference to this scenario. I still get the 2 stage take off when stepping on it.

36 volt cart, good batteries, resistor cart, has 5 matress coils behind the batteries, also has a v-glide.

I cannot find anything loose on the cart. Anyone have any ideas what is causing this 2 stage acceleration???
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Unread 03-26-2015, 09:29 PM   #2
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Default Re: 93 DS resistor cart clunking sound and hesitation

You have only two speeds through the whole range of pedal travel? Should be several; one including all the coils (low speed), the ones in the middle losing coils progressively as you press the pedal, and one with full pack power right to the motor (top speed). My guess is something is amiss with some connections at the Vglide or you've got a broken coil or two.
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Unread 03-26-2015, 10:19 PM   #3
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Default Re: 93 DS resistor cart clunking sound and hesitation

No, maybe i didn't explain right. It starts off when first stepping on pedal. Then as you continue to step on it, there is a real quick hesitation, accompanied with a surge that then smooths out.

All coils are intact and tight. V-glide looks ok, but it seems like the problem would be in the v=glide, since it pretty much happens in the same spot on the pedal?
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Unread 03-26-2015, 10:27 PM   #4
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Default Re: 93 DS resistor cart clunking sound and hesitation

Sounds like the second speed coil or the wire leading to it has an issue. On the V-glide, that would be the 4th contact up from the bottom, and the second wire up on the back.
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Unread 03-26-2015, 10:28 PM   #5
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Default Re: 93 DS resistor cart clunking sound and hesitation

I think 93yellowclubcar has it right, it is a bad stop in the Vglide.

When the solenoid first closes, current flows through all of the coils, so they are all OK.

As You press the pedal and it by-passes the 1st coil, you get the slowest speed.

As You continue to press the pedal and it hits a bad spot when it should be by-passing the 2nd coil, the current goes back through all the coils, hesitation.

As You continue to press the pedal, it by-passes the 3rd coil, bigger jump in speed.
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Unread 03-26-2015, 10:32 PM   #6
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Default Re: 93 DS resistor cart clunking sound and hesitation

Thanks so much for the input! So you think if i replace the v-glide, it will fix the issue?
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Unread 03-26-2015, 10:35 PM   #7
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Default Re: 93 DS resistor cart clunking sound and hesitation

I'd inspect it closely first, could be as simple as the wire being burnt in two at the back of it, or the contact being burnt. I'd just fix what's bad, and only replace the Vglide if the case of it is melted bad enough to cause issues. (Such as making the contacts out of plane)
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Unread 03-26-2015, 10:39 PM   #8
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Default Re: 93 DS resistor cart clunking sound and hesitation

Do you know what color the big wire is that is causing the problem? Today i replaced the fat orange wire, because it looked like it was swelled up about 3 inches down from the vglide terminal. But after replacing it, it did not help.
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Unread 03-26-2015, 10:41 PM   #9
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Default Re: 93 DS resistor cart clunking sound and hesitation



Second speed should be the fat orange one.
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Unread 03-26-2015, 10:44 PM   #10
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Default Re: 93 DS resistor cart clunking sound and hesitation

That is the wire i replaced today, so i guess the wire is not the problem?
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