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Unread 06-25-2011, 12:17 PM   #1
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Default Help....I got sparks!!!

Being the selfish guy I am, I'm posting this question in the best possible place to get the right answer fast!!! Yes, I have searched and now I'm ready to cheat!
My son's 91 CC 36volt resistor cart is sparking at the F/R switch. I've checked for loose wires/connectors. When contact is made in forward or reverse I get a spark, much like an old flash cube right on the backside of the switch underneath the seat. I plan on buying a new switch on Mon., but I thought you guys might save me some $$. Any ideas other than the obvious.
Thanks in advance.
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Unread 06-25-2011, 12:25 PM   #2
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Default Re: Help....I got sparks!!!

you can try taking it off and cleaning it.....sparks are ither loose or dirty connections or both and you eliminated loose......might not need to buy one if cleaning it works.......................................
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Unread 06-25-2011, 07:17 PM   #3
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Default Re: Help....I got sparks!!!

you can take the cleaning one step further and sand the contacts down past any pitts in the copper. start with 220 or 360 grit. then 400, 600, 800, 1000 wet. you can skip a grit or two, but that makes sanding the next step much harder. the end result will be smoove, fresh, like-new copper contacts.

also check for crud & flashing in the plastic housing and springs that may be causing the contacts to bind.
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Unread 11-25-2011, 01:26 PM   #4
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Default Re: Help....I got sparks!!!

Update. New f/r and still have same problem. Arching/sparking when slowly moved back and forth. I'm about to randomly start replacing cables? It seems to be sparking behind the post/lead that runs to the solenoid. Could a bad solenoid cause this?
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Unread 11-25-2011, 01:33 PM   #5
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Default Re: Help....I got sparks!!!

Make sure the terminal end is secure on the cable! I've had them be loose and do this.
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Unread 11-25-2011, 01:48 PM   #6
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Default Re: Help....I got sparks!!!

simple man,
I think that is good advice, I noticed the crimp was loose and decided to swap out the cable and snap!!! Post in the solenoid broke out of the housing, so now I'll get a new solenoid and try a new cable...let you know.
Thanks.
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Unread 11-25-2011, 01:54 PM   #7
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Default Re: Help....I got sparks!!!

i don,t think a solenoid will cause that.................is it at the post that swivel or the lower ones? i think i would start with cables/ends before solenoid.........i have never seen a solenoid do this but that dosn,t mean it can,t.........................................
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Unread 11-25-2011, 02:03 PM   #8
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Default Re: Help....I got sparks!!!

Quote:
Originally Posted by BRS View Post
simple man,
I think that is good advice, I noticed the crimp was loose and decided to swap out the cable and snap!!! Post in the solenoid broke out of the housing, so now I'll get a new solenoid and try a new cable...let you know.
Thanks.
That's a bummer! That is usually caused by a bad connection, causing it to overheat and seize. While you're in there, it wouldn't hurt to check the cable ends at your F-R switch too.
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Unread 11-25-2011, 05:08 PM   #9
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Default Re: Help....I got sparks!!!

YOU HAVE A BAD "LIMIT" MICRO SWITCH on the f/r switch


the function of this micro is to shut down power as the f/r switch is being repositioned..... evidentally this switch is frozen on

if you have replaced the f/r switch and it came with new micros...then i would look for a solonoid with WELDED CONTACTS in CLOSED position ( the solonoid that is not attached to the resistor coils )

this all assumes you wired your new f/r switch and f/r micro switch correctly
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Unread 11-25-2011, 06:31 PM   #10
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Default Re: Help....I got sparks!!!

Quote:
Originally Posted by ForBruce View Post
YOU HAVE A BAD "LIMIT" MICRO SWITCH on the f/r switch


the function of this micro is to shut down power as the f/r switch is being repositioned..... evidentally this switch is frozen on

if you have replaced the f/r switch and it came with new micros...then i would look for a solonoid with WELDED CONTACTS in CLOSED position ( the solonoid that is not attached to the resistor coils )

this all assumes you wired your new f/r switch and f/r micro switch correctly
Yes new micro as well and wired correctly, new cables or at least re-crimping may be in order. Not sure what you mean by a solenoid with contacts in closed position? Micro does shut off, it's not until f/r is moved to f or r...seems like r causes more consistent spark....especially if moved slowly.

Last edited by BRS; 11-25-2011 at 06:33 PM.. Reason: new
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