Bad boy buggy....

chadlogan112

Hi! I recently picked up an older bad boy buggy classic from a neighbor. Parts, service, and help are near impossible to find! When I got it, the batteries were completely dead, it was left out at hunting camp for months. After individually charging batteries, and putting on cart charger, they've sat at 49+ volts for weeks now. Before the key switch was real finicky, if it went back and forth with it, it would go into gear. Now that I've replaced switch with a new one; a new problem has arose. Now putting it in fwd or reverse isn't working, unless I take a wire from the battery pack ground, and touch it to the back of the pds switch. Then it'll go into any gear I touch. Any ideas on what may be wrong? I've cleaned and straightened up almost all wiring, and all looks correct. Recently got frustrated and burnt up the main solenoid, so I have the same one being mailed to me now. But it does have a couple of the larger forward and reverse solenoids. With two tabs on the side as well on each one that two smaller wires hook to, not sure of their purpose. Any help would be much appreciated. The whole 4wd is cool and all, but I'm about to just strip it all down and turn it into a standard 2wd ezgo!

BGW

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ncorry

What kind do you have?

I've been working on a one that is in the 2005-2007 range. It has one motor for the front and one for the rear. If you remove the seat, there's a black plastic flap with 5 sheet metal screws holding it down. Under it, there are two separate Sevcon Millipak controllers (on mine). They are blue. Do not get them wet- they are expensive and impossible to find. There are two solenoids on the passenger side. Mine is full time 4x4, period.

I've read that other model years used one controller to power both motors and you could swap 2x4 to 4x4.

If yours is like mine, let me know and I'll try to help. I had to work way too hard to figure the crap on mine out.

upstatewoodie

I just Acquired a 2006/2007 classic and need to find a wiring diagram so I can start replacing the broken and split wires. all batteries are testing good. I have found the same difficulties find any help or parts around me.

thanks

texashunter74

I have a 2010 and am in the process of taring it down. I Had to replace one of the sevcon millipaks a couple of years ago. I ended up paying $900.

I wonder if it would be possible to switch to a different brand Like the Alltrax or something. I do not know enough yet to make that call

dundeebarnbuggy

Enter ScottyB stage right. He is your [our] god for Alltrax conversions!

Montejano21

Did y’all get any updates on converting to a different controller?