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Unread 09-01-2016, 11:34 PM   #11
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Default Re: Solenoid closing then immediately opening

Load testing batteries doesn't rule out a poor connection or bad battery cable. Either one could cause this.

Checking total pack voltage when you press the pedal will show you if the voltage is dropping out due to a bad connection.

Also check voltage on the negative side to check for a bad ground.
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Unread 09-02-2016, 08:21 AM   #12
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Default Re: Solenoid closing then immediately opening

If the pre-charge resistor is melted, more than likely the controller has failed. A short in the motor can cause this same issue, but it's almost always a controller problem. Typical test procedure for this is to eliminate the motor as possible cause by doing a resistance test on the motor. With the cabled disconnected from the motor, you're looking for continuity between A1 and A2, and continuity between F1 and F2, but no continuity between any of the four posts and the main case of the motor. If the motor passes the continuity test, replace the controller and the pre-charge resistor.
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