Bad F N R Switch or controller?

ClubCar86 · 12-19-2016, 08:01 PM

Just picked up an '86 Club Car from my folks, and found this site. I'd like to fix it for them for Christmas; I'm new to carts and would like to bounce my symptoms off some folks with more knowledge than me (at this point). This is a 36 volt cart. The batteries are charged. With the key in the off position (or w/o the key even in the switch) if the F N R switch is moved from neutral to Forward or Reverse, it wants to lurch and there is a burning smell. This all occurs w/o pressing the gas pedal too - Just from turning the F N R switch. Any thoughts?

Opps, wrong Forum, sorry guys

scottyb · 12-19-2016, 08:07 PM

Hello and welcome to BGW - The 1986 cart has a 5 solenoid speed control system. Electronic speed controllers were introduced in 1992.Likely you have more than 1 solenoid welded closed. I would buy 2 minimum and replace the one closest to the drivers side first, that's the master. Assuming it is not energized continually.

Do you have a DVM or DMM ? Can you test a solenoid?

ClubCar86 · 12-19-2016, 08:10 PM

Thanks Scotty, I was just about to delete this now I've got two threads going (this one in the wrong forum) = Opps. I'm still researching, I was assuming the controller was the box the gas pedal goes into

scottyb · 12-19-2016, 08:20 PM

We can get a moderator to combine the 2 threads when one of them sobers up

The little box at the end of the pedal linkage has a micro (trigger) switch for each of the 5 solenoids. If you jack the cart up you should hear 5 solenoids click as you depress the gas.

rib33024 · 12-19-2016, 08:33 PM

Moved to club car

ClubCar86 · 12-19-2016, 09:08 PM

Thanks RIB! And Scotty, yes I have a DVM, and can test the solenoid, I'll check the sticky's for possible instructions.

Would I still hear the solenoids open if the power is disconnected?

Reviewing some diagrams, its starting to make sense (I've tinkered/Modified the kid's power wheels a bit). I figured this is the next step up. :)

scottyb · 12-20-2016, 08:42 AM

Put the cart on jack stands and remove the seat. Whenyou press the gas you should hear a distinct click from each of the 5 solenoids. The 1st one on the driver's side is the master. It clicks 1st and supplies power to the next solenoid which begins the wheels turning when it clicks, then each subsequent click should result in a slightly faster tire rotation.
As I said before there is a micro switch to trigger each solenoid in the go pedal linkage box. GL

ClubCar86 · 12-20-2016, 12:38 PM

Thanks, I'm reluctant to do that. When the F N R switch is moved to either F or R, I hear electrical popping and crackling back in that area. My plan is to take the solenoids off and test them individually.

scottyb · 12-20-2016, 01:00 PM

AND I would be reluctant to do that

Remove the seat and locate the source of the problem, popping and crackling is usually pretty simple to find.

ClubCar86 · 12-20-2016, 08:51 PM

While under there to get going tonight, I noticed there is a 6th solenoid. Tied to the pull switch in the front of the cab. It is mounted up near the passenger side solenoid, and then wired to the motor:

12-19-2016, 08:01 PM	#1
ClubCar86 Gone Wild Join Date: Dec 2016 Location: Melbourne, FL Posts: 180	Bad F N R Switch or controller? Just picked up an '86 Club Car from my folks, and found this site. I'd like to fix it for them for Christmas; I'm new to carts and would like to bounce my symptoms off some folks with more knowledge than me (at this point). This is a 36 volt cart. The batteries are charged. With the key in the off position (or w/o the key even in the switch) if the F N R switch is moved from neutral to Forward or Reverse, it wants to lurch and there is a burning smell. This all occurs w/o pressing the gas pedal too - Just from turning the F N R switch. Any thoughts? Opps, wrong Forum, sorry guys

12-19-2016, 08:07 PM	#2
scottyb Happy Carting Join Date: Dec 2007 Location: Southern California Posts: 73,399	Re: Bad F N R Switch or controller? Hello and welcome to BGW - The 1986 cart has a 5 solenoid speed control system. Electronic speed controllers were introduced in 1992.Likely you have more than 1 solenoid welded closed. I would buy 2 minimum and replace the one closest to the drivers side first, that's the master. Assuming it is not energized continually. Do you have a DVM or DMM ? Can you test a solenoid?

12-19-2016, 08:10 PM	#3
ClubCar86 Gone Wild Join Date: Dec 2016 Location: Melbourne, FL Posts: 180	Re: Bad F N R Switch or controller? Thanks Scotty, I was just about to delete this now I've got two threads going (this one in the wrong forum) = Opps. I'm still researching, I was assuming the controller was the box the gas pedal goes into

12-19-2016, 08:20 PM	#4
scottyb Happy Carting Join Date: Dec 2007 Location: Southern California Posts: 73,399	Re: Bad F N R Switch or controller? We can get a moderator to combine the 2 threads when one of them sobers up The little box at the end of the pedal linkage has a micro (trigger) switch for each of the 5 solenoids. If you jack the cart up you should hear 5 solenoids click as you depress the gas.

12-19-2016, 08:33 PM	#5
rib33024 ...................... Join Date: Apr 2009 Location: FT Lauderdale FL. Posts: 16,416	Re: Bad F N R Switch or controller? Moved to club car

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12-19-2016, 09:08 PM	#6
ClubCar86 Gone Wild Join Date: Dec 2016 Location: Melbourne, FL Posts: 180	Re: Bad F N R Switch or controller? Thanks RIB! And Scotty, yes I have a DVM, and can test the solenoid, I'll check the sticky's for possible instructions. Would I still hear the solenoids open if the power is disconnected? Reviewing some diagrams, its starting to make sense (I've tinkered/Modified the kid's power wheels a bit). I figured this is the next step up. :)

12-20-2016, 08:42 AM	#7
scottyb Happy Carting Join Date: Dec 2007 Location: Southern California Posts: 73,399	Re: Bad F N R Switch or controller? Put the cart on jack stands and remove the seat. Whenyou press the gas you should hear a distinct click from each of the 5 solenoids. The 1st one on the driver's side is the master. It clicks 1st and supplies power to the next solenoid which begins the wheels turning when it clicks, then each subsequent click should result in a slightly faster tire rotation. As I said before there is a micro switch to trigger each solenoid in the go pedal linkage box. GL

12-20-2016, 12:38 PM	#8
ClubCar86 Gone Wild Join Date: Dec 2016 Location: Melbourne, FL Posts: 180	Re: Bad F N R Switch or controller? Thanks, I'm reluctant to do that. When the F N R switch is moved to either F or R, I hear electrical popping and crackling back in that area. My plan is to take the solenoids off and test them individually.

12-20-2016, 01:00 PM	#9
scottyb Happy Carting Join Date: Dec 2007 Location: Southern California Posts: 73,399	Re: Bad F N R Switch or controller? AND I would be reluctant to do that Remove the seat and locate the source of the problem, popping and crackling is usually pretty simple to find.

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