04 txt shuttle forward is weak, reverse is ok

Psiclown7441 · 05-05-2017, 01:17 AM

Hey guys,

When I got this cart it worked fine in forward and reverse. I rebuilt the rearend because the previous owner had smashed the pumpkin in a rock and the gears were whining. (Flattened). New bearings, full 12:1 gear set, axle seals. I swapped the stock motor out with a mild upgrade from Plumbquick. After putting back together it didn't have much torque at all going forward but strong in reverse. I replaced the F/R switch with a heavy duty and same problem. I checked every wire by hand making sure they are routed correctly. So before, cart ran fine. After new trojans (replaced 4, 12v marine baterries it came with) 8, 6volt, new motor, new rearend and f/r switch, it has crap for power in forward. Tested all batteries under load and across the pack reads 54v at full charge.

I'm thinking I got the wrong motor shipped or something. Can pds/series motors interchange without a problem?

Thanks very much for the

H-E-L-P.

Psiclown7441 · 05-05-2017, 11:50 AM

I confirmed with Plumbquick the motor is correct. He said the controller is reversed but I checked the wiring. I swapped the wires on the F/R switch in the 3 and 9 o'clock position and that only sends the cart forward while the switch is in reverse and vice versus. Same shudder forward after the swap test.

mutant · 05-05-2017, 01:31 PM

jonnieB or scottyB need to chime in but i have seen several times that these symptoms have occurred on this forum...
the problem may be with the small wires running to the controller telling the unit that forward is reverse-sending the unit to half speed-or something like that.....
what is your cart-PDS or series?
what controller are you running?

Psiclown7441 · 05-06-2017, 11:44 AM

Yeah I read tons of threads and tried everything that others have done to no avail. I read one guy fixed it with a new solenoid somehow. I picked one up yesterday and haven't installed it yet. The guy at the shop said the same thing about the little controller wires 1,2,3. I'll get the controller info in a bit. I think it has been replaced because there is an orange wire not connected but no terminal like the diagram shows. But again it didn't have this problem when I first got it so don't think that wire does anything. Maybe its the half speed wire. Ut isn't it supposed to be connected to activate the half speed anyway? I don't think I messed with anything under the seat prior to the f/r switch which is why I haven't looked at those 1,2,3's. Series cart, with the big lever for f/r next to the E-brake handle between the seats and no tow/haul switch. Thanks for the reply ;)

Psiclown7441 · 05-08-2017, 08:10 PM

I can't tell what controller it is without taking it off, I'll get to it when I have some time. Couple pics.

Psiclown7441 · 05-09-2017, 11:21 PM

Hey guys,

Still trying to figure out this thing. New solenoid still no dice. Would someone mind letting me know a couple wiring questions on the pictures?

I tested the pack again under load and it went from 51 to 46.8 in both fwd and reverse.

I went across the individual batteries again and all were 6.4V. One flashed 4.9v for a quick second then back to 6.4V, might have been a dvg lead connection issue, but seemed a little weird.

Thanks for the help

orangeman6 · 05-10-2017, 12:18 AM

Psi, I can't really help you with your problem, but I can tell you that the first picture in your last post is the 12v fuse block. The green wire you ask about in your second picture is the same green wire you see in pic 1 attached to the fuse block. Ezgo used the + of battery 5 and the negative of battery 6 to get the 12v for that accessory fuse block in pic 1.

I would suggest posting some additional pictures for the experts here. Don't zoom in, try to show as much of the wiring (Don't think you need the 12v stuff) as you can. Guys can zoom in On what they want , but they have to be able to see where wires are going.

Good luck.

Psiclown7441 · 05-22-2017, 09:12 PM

Good idea, ok here's a top down pic along with a pic of the throttle sensor. I can tell it's been replaced or at least the wires have been from the fresh connectors. Also the ground has been cut off. Lemme know if things look right. Gonna test the batteries one more time under load uphill until it stops. Don't think it's the batteries though as it goes uphill in reverse with 3 people in it with no problem. Slower of course, but way more torque to carry the load.

Seaquell · 05-23-2017, 07:29 AM

This may sound dumb but can you switch the terminals on the motor so you get your full reverse power in forward?

scottyb · 05-23-2017, 07:50 AM

Is the cart slower and stronger in reverse?

05-05-2017, 01:17 AM	#1
Psiclown7441 Not Yet Wild Join Date: Dec 2015 Posts: 28	04 txt shuttle forward is weak, reverse is ok Hey guys, When I got this cart it worked fine in forward and reverse. I rebuilt the rearend because the previous owner had smashed the pumpkin in a rock and the gears were whining. (Flattened). New bearings, full 12:1 gear set, axle seals. I swapped the stock motor out with a mild upgrade from Plumbquick. After putting back together it didn't have much torque at all going forward but strong in reverse. I replaced the F/R switch with a heavy duty and same problem. I checked every wire by hand making sure they are routed correctly. So before, cart ran fine. After new trojans (replaced 4, 12v marine baterries it came with) 8, 6volt, new motor, new rearend and f/r switch, it has crap for power in forward. Tested all batteries under load and across the pack reads 54v at full charge. I'm thinking I got the wrong motor shipped or something. Can pds/series motors interchange without a problem? Thanks very much for the H-E-L-P.
Psiclown7441 Not Yet Wild Join Date: Dec 2015 Posts: 28

05-05-2017, 11:50 AM	#2
Psiclown7441 Not Yet Wild Join Date: Dec 2015 Posts: 28	Re: 04 txt shuttle forward is weak, reverse is ok I confirmed with Plumbquick the motor is correct. He said the controller is reversed but I checked the wiring. I swapped the wires on the F/R switch in the 3 and 9 o'clock position and that only sends the cart forward while the switch is in reverse and vice versus. Same shudder forward after the swap test.
Psiclown7441 Not Yet Wild Join Date: Dec 2015 Posts: 28

05-05-2017, 01:31 PM	#3
mutant Gone Wild Join Date: Aug 2014 Location: fletcher,nc Posts: 601	Re: 04 txt shuttle forward is weak, reverse is ok jonnieB or scottyB need to chime in but i have seen several times that these symptoms have occurred on this forum... the problem may be with the small wires running to the controller telling the unit that forward is reverse-sending the unit to half speed-or something like that..... what is your cart-PDS or series? what controller are you running?

05-06-2017, 11:44 AM	#4
Psiclown7441 Not Yet Wild Join Date: Dec 2015 Posts: 28	Re: 04 txt shuttle forward is weak, reverse is ok Yeah I read tons of threads and tried everything that others have done to no avail. I read one guy fixed it with a new solenoid somehow. I picked one up yesterday and haven't installed it yet. The guy at the shop said the same thing about the little controller wires 1,2,3. I'll get the controller info in a bit. I think it has been replaced because there is an orange wire not connected but no terminal like the diagram shows. But again it didn't have this problem when I first got it so don't think that wire does anything. Maybe its the half speed wire. Ut isn't it supposed to be connected to activate the half speed anyway? I don't think I messed with anything under the seat prior to the f/r switch which is why I haven't looked at those 1,2,3's. Series cart, with the big lever for f/r next to the E-brake handle between the seats and no tow/haul switch. Thanks for the reply ;) Last edited by Psiclown7441; 05-06-2017 at 11:45 AM.. Reason: Missing info
Psiclown7441 Not Yet Wild Join Date: Dec 2015 Posts: 28

05-10-2017, 12:18 AM	#7
orangeman6 Gone Wild Join Date: Sep 2016 Location: Northern California Posts: 1,300	Re: 04 txt shuttle forward is weak, reverse is ok Psi, I can't really help you with your problem, but I can tell you that the first picture in your last post is the 12v fuse block. The green wire you ask about in your second picture is the same green wire you see in pic 1 attached to the fuse block. Ezgo used the + of battery 5 and the negative of battery 6 to get the 12v for that accessory fuse block in pic 1. I would suggest posting some additional pictures for the experts here. Don't zoom in, try to show as much of the wiring (Don't think you need the 12v stuff) as you can. Guys can zoom in On what they want , but they have to be able to see where wires are going. Good luck.

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05-23-2017, 07:29 AM	#9
Seaquell Gone Wild Join Date: Nov 2016 Location: Wilmington NC USA Posts: 268	Re: 04 txt shuttle forward is weak, reverse is ok This may sound dumb but can you switch the terminals on the motor so you get your full reverse power in forward?

05-23-2017, 07:50 AM	#10
scottyb Happy Carting Join Date: Dec 2007 Location: Southern California Posts: 73,410	Re: 04 txt shuttle forward is weak, reverse is ok Is the cart slower and stronger in reverse?

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