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Electric EZGO Electric EZ GO Marathon, Medalist, TXT and RXV.



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Unread 02-11-2018, 04:22 PM   #1
Not Yet Wild
 
Join Date: Jan 2018
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Default 2009 RXV brake issue

I replaced the wire harness in a 2009 RXV. When I got to the motor/brake connection the weather pack connection did not match the metri pack connector on the new harness. I did not know at the time there was a conversion adapter for this. I clipped off the old weather pack and installed the new metri pack connector and it went together fine. I think. When I powered up and tested everything I could at first smell an electrical smell and then had smoke coming from the brake controller. I shut down immediately. The brake was really hot to the touch from this short test. I had the cart on jacks when I did this. A little back ground on this cart. I got it from a golf course that closed down. This cart sat and did not move for almost one year. Rats ate out most of the wiring harness. The wheels were locked up and it could not be moved without dragging it. I replaced the batteries, a full new wire harness with solenoid, a new charging harness. I also replaced a part on the controller. I was not sure the controller itself or the motor was any good. On my test run today, the motor turned fine and the controller seemed ok. My understanding is the RXV wont do anything if the controller is bad. Will a simple brake replacement take care of the issue or should I be looking for something else. I appreciate this site, between all the info and videos on line I have learned so much, Thanks from New Mexico, 200 miles from everything. Joe
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Unread 02-11-2018, 06:53 PM   #2
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Join Date: Feb 2016
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Default Re: 2009 RXV brake issue

It sounds like the parking brake isn't releasing completely. If the brake is dragging it will get very hot. When the parking brake drags it smells just like burning electrics. If you didn't replace the brake it may be corroded from sitting a year. The brake is only a parking brake and is either on or off. All the normal braking is done by the motor. It has a disc that is squeezed between a movable metal plate and the outer case of the brake by springs. The disc is keyed to the motor shaft. When the brake is released an electro magnet pulls the movable plate away from the disc allowing it to rotate. If it can't move freely because of corrosion it will drag. I would take the brake off and take it apart to check it or just replace it.

If you take the brake off be sure and follow the procedure in the manual to replace it. You have to connect the brake and put it in tow mode (to release the brake) before you tighten the bolts. That allows the brake to align properly when you tighten the bolts.
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Unread 02-14-2018, 12:29 AM   #3
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Default Re: 2009 RXV brake issue

I appreciate your reply. I ordered a new motor brake and it came today. When I took the old one off, I knew something was wrong with it as the screws were caked with brake dust and carbon deposits. The motor plate had burnt on carbon deposit and was filthy. I also noticed that the bottom of the motor brake had a chip on it where a piece of the metal broke off. I took a lot of time to clean the motor plate surface. I used awesome (at Dollar Store, best stuff ever) some fine grit sand paper and ultra fine steel wool. I removed all the fine dust with some WD40 on a microfiber towel. It cleaned up well and looked like a new surface. I installed the new brake and followed the exact directions and advice of CGTECH. It went on with no issue. My advice to anyone doing this brake install to follow those directions exactly (and Yes, as per his instructions, I had a beer to celebrate it was done) This is my first time ever taking on a project like this. I cant thank those who took the time to answer my questions enough. BobBoyce, CGTECH and RNGilliland deserve a special shout out. THIS SITE IS GREAT.
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Unread 02-14-2018, 12:49 AM   #4
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Default Re: 2009 RXV brake issue

Glad it went awesomely for you.
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