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Unread 02-23-2016, 08:58 AM   #1
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Default 1996 Continously Variable Potentiometer or CONTROLLER

Hey everyone I've searched and searched and can't find the solution to the problem I am having. I have a 1996 CC that has the continuously variable POT and sometimes when driving along it will loose power. This only happens when it is at WOT because if I let off the pedal just slightly it will get power again. Less seldomly, this will happen when taking off from being stopped. A quick release of the throttle and we are moving along again. I have tested the outputs of the pot using a DVR set to ohms across the yellow and purple wires and get 0 at rest and then climbing as I press the pedal to eventually WOT and reading infinit. The manual says it should top out at 5k but I've read on here that it tops out at infinity so I am a bit confused with that. Basically I am trying to figure out if it is the limit switch at the cont var pot, the cont var pot itself or the speed controller. Any help is greatly appreciated. Thanks!! The batteries hold a good charge and the cart will run several miles before needing a charge. They are old however.
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Unread 02-23-2016, 09:46 AM   #2
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Default Re: 1996 Continously Variable Potentiometer or CONTROLLER

Sounds like a Potentiometer issue. Very common. I've seen them get out of range many times and behave the exact same way. The MCOR4 conversion kit, number AM293201 would get you up and running again. It's a very common issue.
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Unread 02-23-2016, 09:54 AM   #3
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Default Re: 1996 Continously Variable Potentiometer or CONTROLLER

Test your pot output again. 0-5k is ideal 0-6500k is usually about the max the control will be able to read. A signal beyond that is off the scale, over the limit, and the control basically looses throttle signal at that point.

The solution may be as simple as putting a block on the floor to stop the gas from hitting such high numbers. Or adjusting the pedal linkage.
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Unread 02-23-2016, 10:04 AM   #4
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Default Re: 1996 Continously Variable Potentiometer or CONTROLLER

Great thanks Guys!! It does have a new pedal so the linkage may be the issue. If it isn't, sounds like the mcor conversion is the way to go. Thanks again
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Unread 02-23-2016, 10:28 AM   #5
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Default Re: 1996 Continously Variable Potentiometer or CONTROLLER

First try adjusting the linkage. I was able to do it on my first cart, it was a 96 with the pot box.
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Unread 03-01-2016, 10:41 PM   #6
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Default Re: 1996 Continously Variable Potentiometer or CONTROLLER

I adjusted the linkage and all is well so far I think that may have been it. I tested with a dvm and was getting 0-5.5k give or take. Thanks again for all the help!
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Unread 03-01-2016, 11:02 PM   #7
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Default Re: 1996 Continously Variable Potentiometer or CONTROLLER

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Unread 03-01-2016, 11:10 PM   #8
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Default Re: 1996 Continously Variable Potentiometer or CONTROLLER

Quote:
Originally Posted by Golfinw71 View Post
I adjusted the linkage and all is well so far I think that may have been it. I tested with a dvm and was getting 0-5.5k give or take. Thanks again for all the help!
That's awesome. Keep a close eye on it though. Those pot-boxes were very problematic. It's incredible that it's lasted this long.
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