04 club car ds with perfomance problems

blake80

my dad has a '04 club car dc. 48v stock controller less than year old batteries. we just up graded the stock motor to PLUM QUICK BANDIT motor. let me first say this, I AM NOT TALKING BAD ABOUT PLUM QUICK AT ALL, THEY HAVE BEEN VERY HELPFUL, I AM ONLY POSTING HERE BECAUSE THEY WILL NOT BE OPEN UNTIL MONDAY. so, that being said. since we put the new motor in, some problems have come about. my dad took the cart back to the shop where he got it from. the cart had no power, in fact the stock motor would perform better. i called and talked to robby at pq. he told me what to check such as the batteries, gas peddle, etc..... well the cart shop said the problem was the charger plug on the cart, so he replaced it. now at this point we had not had time to really check it out since we got it back. well today he took it to his hunting club to ride around. short distance trips everything was fine until he went for a longer ride. cart was going fine then it just stopped. waited a minute and it would go again. it took about a hour to get it back to his truck. he flipped the seat up and could smell something burning. he reached in to feel the motor and it was fire hot.

so tomorrow im going to check out the all the cables and make sure everything is tight. im also going to load check the batteries per robbies instructions. but, does anyone have any suggestions as to what the problems could be and how to check for them.

BGW

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OLD MEC

HEAT IS CAUSED BY RESISTANCE, and the end results of resistance can be caused by many things. Were you pulling heavy loads like 4-6 people or climbing hills or running for long distances at slow speed, possibly in loose soil or mud? Plumb Quick like all high torque-high speed motors dont like slow speed. All of course will cause heat build up way above normal. When you ordered your motor did you also update the controller to higher amp rating ( stock about 250-275 higher amp rated to 500 and up amps ) and switch from 6 guage to at least 4 guage or better yet 2 guage ( ALL multi stranded welding cable stock ) cables at the same time? Too high a temps inside controller with too low amp draw rated will make it shut down and cool off before restarting.
Good way to test is run cart around for awhile at normal speed then quickly lift seat and check all cables, cable connections, F&R control itself and connections, solenoid and connections, some heat is normal but if you find a hot spot this is your problem to solve.
Just a thought can you push your cart by hand with not much resistance when empty and on hard surface as brake drag, wheel bearing drag, large diameter lugged tread tires, etc can cause high drag especially at low speeds under load.

blake80

thanks boss man. we are checking things out right now. we did just discover that one of the control wires going to the solenoid was very loose.

OLD MEC

Hope thats all you need to do. Could cause some high speed chattering of solenoid, maybe enough to cause heat buildup?

blake80

The sad part of all of this is that the cart shop didn't check any of this out like he should have

OLD MEC

Too much speed of getting carts out of shop and getting paid in the USA today. Most auto-golf-truck shops are not mechanics just parts changers. If one thing doesnt work change another ( what the "H", customer is dumb enough to keep paying for my mistakes? ) might even give me a pat on the back if I finally find right answer?

OLD MEC

Sorry got cut off in mid post???
You must do like most smart people do and first ask around to find a quality shop and or dealer ship ( I find all kinds of dealerships far too often have low standards of quality ) that others have had good luck with, then take a close watch on billing and time charged.
ASK AROUND IN OUR FORUM for shops close to you if any are available. I know time is against you because you want to enjoy your cart, but will pay off in the long run.

blake80

I totally agree. Well I got to busy finishing my cage for my cart and didn't mess with dads. But. I'm going to call robbie at PQ tomorrow and maybe take it to him