Positive Battery terminal Sparks when I press the Accelerator

think92

I have a 2003 ez-go golf cart with the tow/run switch. I have tried the diagnostic beep test and got no diagnostic beeps back. When I push down the accelerator, the positive terminal on the battery that goes straight to the controller starts sparking right where the cable connects to the terminal. It's melting the end of the cable where the connector is and I can't drive my cart. :(
Any help would be greatly appreciated.
Thank you!

BGW

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mikesmotortoys

Sounds like a bad connection...

think92

Bad connection to what? All of my battery cables were just replaced with a heavy guage welding wire. all wires to and from the batteries are very tight. I think i noticed when I push the accelerator down a lot I get a BIG spark, if I push it a little bit, it has a smaller spark... does that help?

mikesmotortoys

Are you sure your cable is properly crimped? Is this a set of cables someone made or are they a manufactured set?

A spark will come from a loose connection...

think92

yea, it was working just fine with the cables that are on there for a couple of months until one day it just started doing this. I just went out there again and looked at it again and I noticed it does not move either when I push the Accelerator.
The cables were professionally made in a machine shop... things cost me 120$... grrr

Could this be something to do with the speed controller or something? Since it's a big spark when pedal fully pressed and little/no spark when pedal barely pushed??

mikesmotortoys

Where exactly does the spark come from? Battery terminal post? Cable lug where is joins the cable?

think92

well where the cable connects to the post the rubber at the end of it is getting melted. So I think it's coming from right at the end of the cable very close to the + post.
it doesn't spark or anything when it's just sitting there either...

mikesmotortoys

As a precaution - take the cable off and try to re-crimp it with some vice grips. Look it over really well before and see if it seems loose inside.

sak00

Sounds like a bad crimp job on the cable end to me.

think92

I just pulled it off and checked it out all the wiring is fine still, just the heat wrap has melted a little on the bottom but the connections are VERY tight. I did squeeze it with some vice grips though and still I could not get it any tighter...

All the cables are only a couple months old, which is weird cause the cables before were practically falling off just hanging by seriously a thread and I never had a problem like this...