97' 48V series with dead spot problems

UltraFast

I just bought a 1997 CC 48V series cart. There is a dead spot in pedal on the lower 1/3. I downloaded a manual but, it is for 98-99 models more specifically aug. of 97 thru 1999. I used the serial number decoder and mine doesnt make any sense. The first numbers are A9753. If the decoder is correct that would be a 1997 model built in the week 53? sounds impossible. Anyway, I removed all resistors from potentionometer and checked resistance. This is the readings I got; beginning with post 3-4, 593 ohms, post 4-5, 402 ohms, post 5-6, 487 ohms, post 6-7, 787 ohms, post 7-8, 1042 ohms, and post 8-9, 0 ohms.
Because I do not know the exact model CC I have I cannot use the standard the manual gives me for resistance check they are nothing alike. Can someone help decifer this?

BGW

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Golfdog

Does all appear a bit confusing. If your potentiometer is a 3 wire one (excl. the microswitch) then I would go with the 98-99 manual. It should have a silver speed controller with a 5K - 0 throttle. The older carts had a black controller with a 2 wire potentiometer and a 0 - 5K throttle. The resistor values were I think 300, 390 ,750, 1000 and 2200. Between the two they came out with a fully variable potentiometer that fitted on the frame rail below the pedal cluster.

UltraFast

I just went and checked, the controller is in fact black and the potentiometer is directly under the driver in battery compartment. So, I guess this means I should use the 1996 manual? The values you gave are for the silver controller or the black one? The actual values I took seem to be all over the place. If I knew what they should be could I use modified (attach proper fittings) Radio Shack resistors?

Golfdog

If your pot. is the 2 wire one, from posts 1 and 3 only then the values given are for that pot. as per www.golfcartpartsdirect.com The values for the 3 wire pot. are 0, 910 ,750 ,910, 1000, 1000, 1000 (from posts 2-9)

UltraFast

Thank You GolfDog it is all starting to make sense now. 2 or 3 wire thing is bugging though. as I look at the pot from resistor side, on post 1 there is a wire also on post 3. then on post 9 there is also a wire. the plug has only 3 pins. Do I have 2 wire or 3 wire pot? Thanks

Golfdog

You have a 3 wire pot. The wire to post 3 is usually to post 2 with a 0 ohm resistor between 2 and 3. I am a bit confused by the black controller which if original was usually used with the 2 wire pot. Is there any part or model # on the controller ?

shadowman

they used a triangle shaped 3 wire plug on the 96 with the black controller....................

Golfdog

I assume that that particular black controller has the 5K - 0 throttle.? I was always led to believe that the black controllers were 0 - 5K , 2 wire throttle type and that the silver controllers were the 3 wire 5K - 0 throttle type. (see www. alltraxinc.com document depo)

shadowman

my 96 has the 3 wire grey triangle plug for the pot and the black T shaped controller.....lots of guys have never seen or heard of this controller..........its been a while since i messed with it but i remember it being the 5 to 0 pot...................................

UltraFast

Wow, I always seem to buy the weird thing>>LOL. I had the wrong setting on my ohm meter for the last resistor, #6 is in fact a 2200 ohm resistor. I also have a model number from the controller. It is 1204-410 and is definetly black. With the new resistor value I have it looks likely that I have a 2 wire pot. Perhaps the controller model number will help give the final answer.

Edit...I am blind or stupid. I just took off my back cover to check someting unrelated and noticed I have a silver controller not black. It looks black from different angles. What does this change? According to my resistor readings I should use a 1996 service manual, right?