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Unread 10-08-2014, 05:37 PM   #1
Not Yet Wild
 
Join Date: Aug 2012
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Default 2003 DS IQ 48 volt cutting off under load then limp mode

I recently purchased an 03 DS IQ 48 volt and I have a small hill about six or seven feet high and my cart will cut out when I'm half way up the hill. I have had a lot of carts and none have ever done that. I noticed that I could go up the hill slowly at 3/4 throttle the whole way but if I try again and hit close to full throttle then it shuts off. Any ideas? Btw, it does this when I just get on the cart so it's not hot from running around.

Another issue that I'm not sure if it is related or not: the cart would only go about 11 miles per hour, I took the speed magnet out and broke off about 1/3 of it to get rid of the top speed control and the cart immediately went to 13.5mph. Then I pushed the petal as hard as I could (it was already at the floor before I pushed hard in the middle of the pedal) and the cart went 16.5 mph. This made me look at the throttle linkage and I saw significant wear on the black bar that goes into the accelerator box so I rigged it to be able to have the black shaft twist further this more throttle. The result was the cart would take off way faster but within a few seconds it would shut off and go into limp mode. I would have to turn the cart off, put into tow mode and back to run to get it out of limp. I hate to admit but I tried this about 8 times and I always ended up with the same result, I would apply less throttle but once it got to 15 or 16 mph and I pushed the pedal for more throttle the cart would go into limp mode. Any ideas? Is it a controller issue or am I somehow sending too much voltage signal into the throttle input?

For what it's worth, I don't think it has to do with me modifying the magnet as it ran fine ( and still does) over the stock speed after I modified it but it still had the same feel as before the mod as it always felt like I wasn't full throttle (apparently I wasn't). Also, I did the same mod on another 2003 ds I owned before and it ran great at 20 mph or so for two years and I sold it.

Thanks for reading this long post and any advice would be greatly appreciated!!!

Last edited by 92timbrandenburg; 10-08-2014 at 05:38 PM.. Reason: Typo
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Unread 10-08-2014, 07:43 PM   #2
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Default Re: 2003 DS IQ 48 volt cutting off under load then limp mode

I know from what you have said you will not agree with me, but here goes. Put a high speed magnet in it. You may fool the computer some of the time but you can't fool it all the time. recheck you pedal linkage it may be slipping some.

Others may have a better answer this is just my thinking.
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Unread 10-08-2014, 08:03 PM   #3
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Default Re: 2003 DS IQ 48 volt cutting off under load then limp mode

The magnet sounds like it is ok, but the worn throttle linkage needs to be addressed. I would get the parts and fix it then you should be good to go.
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Unread 10-08-2014, 09:39 PM   #4
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Default Re: 2003 DS IQ 48 volt cutting off under load then limp mode

Put a high speed magnet in it that's made for your motor. Not a modified piece of a magnet. Either the magnet has fallen apart and crapped out on your, or your speed sensor itself is bad. Regardless, It's best to replace the magnet with something good.
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Unread 10-09-2014, 01:46 PM   #5
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Default Re: 2003 DS IQ 48 volt cutting off under load then limp mode

Thanks for the replies, what do you think is the reason it cuts out while accelerating up a small hill even before the magnet mod then? Thanks again!
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Unread 10-09-2014, 01:49 PM   #6
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Default Re: 2003 DS IQ 48 volt cutting off under load then limp mode

I forgot to add that the pedal linkage is definitely worn, can you twist the linkage too much and cause a computer fault by too high a voltage or does it just read voltage to a certain point and then flatten out? Thanks again, the input is appreciated.
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