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Unread 07-10-2019, 02:35 PM   #1
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Default Scraping sound then intermittent speed

2002 Club Car DS, D&D Series motor serial #6497, manufactured 2015. Top speed is 28 mph, so I might have an upgraded controller. I think everything else is stock. Yesterday I was driving for about 20 minutes at top speed when I heard a loud scraping sound coming from the rear and more towards the passenger side. I slowed down and crawled for another minute and the sound went away or at least so minimal that I didn't notice. However, I could not reach full speed again. It would ride maybe 12 mph's and then have a quick burst of speed for 3 seconds and then go back to 12 mph. I made it home, charged the batteries and took it for a ride this morning. There is a very faint scraping sound every so often and I still have the intermittent speed. I'm not that electrically or mechanically inclined but I will attempt anything and I do proceed with caution.

Thank you in advance for any advice.
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Unread 07-10-2019, 04:30 PM   #2
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Default Re: Scraping sound then intermittent speed

Is this a Series or Sepex cart? (FNR lever or Fwd/Rev switch)
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Unread 07-10-2019, 05:32 PM   #3
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Default Re: Scraping sound then intermittent speed

There is a forward/reverse toggle switch by the charging inlet.
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Unread 07-10-2019, 05:47 PM   #4
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Default Re: Scraping sound then intermittent speed

There is a two run switch. There are 3 separate wires (red, black, green) coming out of the motor end. There are two smaller terminal bolts and two larger, so all things point to a regen.
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Unread 07-10-2019, 06:52 PM   #5
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Default Re: Scraping sound then intermittent speed

Ok, so per CCfanatic from another post, "Try to push the cart with it in run and no parking brake. It should make a beeping sound and show resistance. If not, you have a bad speed sensor". I pushed my cart in my garage with no resistance and no beeping. I then pushed it out of my garage and down my driveway (slight decline) with no resistance and it started to pick up speed and then it finally started beeping. I guess I have a speed sensor issue? Would that make that scraping sound or cause the motor to make that sound?
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Unread 07-10-2019, 07:04 PM   #6
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Default Re: Scraping sound then intermittent speed

You likely have a linkage issue between the motor and transfer case/bell housing....speed sensor won’t make a noise.
Your sensor may or may not be at issue. You have something that has either failed or become damaged either inside the motor or the linkage....
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Unread 07-10-2019, 08:25 PM   #7
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Default Re: Scraping sound then intermittent speed

Not sure about your setup, but 28 mph with a stock motor and wheels may be enough to over-speed the motor. Extended running over 6000 rpm could be the problem.

This would cause the armature to come apart and scrape the field windings. This is a fatal motor issue.
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Unread 07-10-2019, 09:50 PM   #8
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Default Re: Scraping sound then intermittent speed

That is a D&D Speed Motor so you are pushing it for sure. If that is stock 18" tires you are pushing over 6400rpm may be within the D&D specs. I do not know. The speed sensor has failed and more than likely the magnet has failed also. Also brushes will make some noise as they get worn. As others mentioned it could be the armature or more, you just have to inspect it and see.
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Unread 07-11-2019, 07:17 AM   #9
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Default Re: Scraping sound then intermittent speed

Alright, I guess I will pull the motor. I've never had any experience with this, so it should be enlightening. What I've researched so far is to apply brake, chock, switch to tow, pull off negative's to battery, (I'm assuming every negative or maybe it's just the first battery in the bank?), either jack up on stands to reach motor from bottom or remove body to remove motor from top. I'm going the remove body method. Unplug electrical connections to the motor and remove bolts using two wrenches. Should be fun.
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Unread 07-11-2019, 11:56 AM   #10
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Default Re: Scraping sound then intermittent speed

Before I would go thru all that trouble I would remove the speed sensor and check for damage. It's just two screws, it could save you a lot of trouble.
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