RXV stuck in reverse

Genlee

My 2009 R.X.V. lunges toward reverse and the alarm sounds but it doesn't move. I found the cable from the solenoid to controller was burnt at the controller and the controller was melted around the terminal. I replaced the key switch, cable and the controller. It still does the same thing. The pedal seems to be up all the way and the fuse looks good. Anyone have any ideas?

BGW

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usgicollector

Sounds like you need a new motor brake. Put cart in tow, key switch to N can you push the cart?

Genlee

Yes

usgicollector

This only happens in reverse? Not forward?

jkredman

“Lunges toward reverse”? Is the key turned to reverse? Does the alarm sound if the key is set to forward?

If you can move the cart in tow mode, the brake is releasing. However that doesn’t mean the cart is not failing a power on test.

Could the lunge you describe be a hard jerk or hard but short movement of the cart?

For safety purposes the cart will attempt to turn the motor against the motor brake at power on. If the motor can turn about 1/4 of a full rotation it fails the test. This is commonly referred to as the ‘twist test’.

The motor brake could be failing.

That said, I am wondering about the overheating between the solenoid and the controller. Something was drawing a whole lot of current or that connection developed greater than normal resistance. Or perhaps the connection was loose and there was some arcing? Do the High amperage (power) cables have corrosion on them?

Genlee

The Alarm sounds in all directions and neutral. Yes the cart jerks back but the tires are locked. Burnt cable was tight and I didn't notice any corrosion.

jkredman

What shape is the wiring harness in?

Something’s amiss here. If the reverse buzzer sounds in all keyswitch positions, there is a voltage leak to the buzzer somewhere.

I read that you replaced the controller. It’s unlikely that 2 controllers would exhibit the exact same issue, unless the second controller was immediately failed when power was applied.

Are there any splices in the wiring harness?

The stock EZGO harness is clean. There are no wire splices. I’m trying to think / figure out how the reverse buzzer would be engaged all the time. We’re there any modifications to the key switch wiring or the state of charge connector/ wiring. These would both be behind the dash board.

Genlee

It seems clean, no splices that I know of

rockfordpi

I had a similar issue. Buzzer sounded in all key positions, cart would only go forward and at very slow speed. Buzzer wires had been cut, but were properly spliced back. Never found problem, replaced controller and that fixed it.

cgtech

Since you already replaced the controller, based on what you describe, we have 2 things left. The motor brake (not my number one suspect since you have "solid on" reverse buzzer in all "on" key positions). Or corrosion inside the harness. Peel back the black wire loom on the wires where they pass by the batteries on the passenger side going back to the motor (8 small wires, 2 for motor brake, 2 for temp sensor, 4 for encoder). Check for "salty" appearance on the wires. Other spot is where wires pass in front of batteries to go over to gas/brake pedal area, and the area in the pedal well. Also check all those for "salty" appearance. I have seen this corrosion problem in the harness so many times I couldn't even count them....