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



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Old 08-27-2012, 06:28 PM   #1
skeeter621
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Default Troubleshooting a Resistor

Does anyone know how to troubleshoot a resistor for a 1981 Marathon?
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Old 08-28-2012, 09:36 AM   #2
rlw
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Default Re: Troubleshooting a Resistor

Welcome to BGW!

I've got an '84 Marathon resistor cart. I'm no expert, but I took it apart and put it back together, and it runs.

I'd be glad to help you, but need more information. Photos under the seat would be a plus, as well.

What's the basic problem (won't run, runs poorly, etc.)?
What's the battery-pack voltage?
Do you hear a click when the FNR switch is in "F", the key is "ON", and the pedal is depressed?

Let's get some more info and we'll see what we can do.

RLW
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Old 08-28-2012, 09:44 AM   #3
JohnnieB
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Default Re: Troubleshooting a Resistor

Quote:
Originally Posted by skeeter621 View Post
Does anyone know how to troubleshoot a resistor for a 1981 Marathon?
In general terms, disconnect it and use an Ohmmeter.
Need to know which resistor to be more specific.
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Old 08-28-2012, 07:50 PM   #4
skeeter621
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Default Re: Troubleshooting a Resistor

Quote:
Originally Posted by rlw View Post
Welcome to BGW!

I've got an '84 Marathon resistor cart. I'm no expert, but I took it apart and put it back together, and it runs.

I'd be glad to help you, but need more information. Photos under the seat would be a plus, as well.

What's the basic problem (won't run, runs poorly, etc.)?
What's the battery-pack voltage?
Do you hear a click when the FNR switch is in "F", the key is "ON", and the pedal is depressed?

Let's get some more info and we'll see what we can do.

RLW
Ran fine, till it got hung up on a fallen tree! Got it free then noticed it was sluggish taking off.
Checked wires, batteries, accelerator, etc, all looks good.
Runs fine, once it gets moving,
It's just very slow starting out, and does not like hills anymore!
I found the wiring diagram on line and suspect the resistor bank for the starting winding is burnt. I'm looking for a way to verify this. Thanks for any help you can offer.
-Skeeter
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Old 08-28-2012, 08:00 PM   #5
skeeter621
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Default Re: Troubleshooting a Resistor

Quote:
Originally Posted by JohnnieB View Post
In general terms, disconnect it and use an Ohmmeter.
Need to know which resistor to be more specific.
I gave it a quick look and didn't find any info.
Will remove unit and look for clues and take photos
Thanks ,Skeeter
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Old 08-29-2012, 08:28 AM   #6
rlw
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Default Re: Troubleshooting a Resistor

Quote:
Originally Posted by skeeter621 View Post
Ran fine, till it got hung up on a fallen tree! Got it free then noticed it was sluggish taking off.
Checked wires, batteries, accelerator, etc, all looks good.
Runs fine, once it gets moving,
It's just very slow starting out, and does not like hills anymore!
I found the wiring diagram on line and suspect the resistor bank for the starting winding is burnt. I'm looking for a way to verify this. Thanks for any help you can offer.
-Skeeter
JohnnieB's right, disconnecting and checking with an ohmmeter is the place to start. A photo of the resistor bank will help, too.

When I rebuilt mine, I took it out of the cart, disassembled it, shined up all of the bolts and the part of the coils that contact them with a wire wheel, then put the whole thing back together. I also made sure that none of the coils were touching their neighbors.

You may have bent it up running over the tree or caused a bad connection between the coil and the wiper board.

Seems kind of odd that it "does not like hills anymore!" You probably should also check the batteries. Mine "doesn't like hills", but that's mostly because I've got 9 year old batteries in the thing. When I go up a hill, the pedal's floored, and I"m bypassing the resistor completely right then. Running over the tree could have also poked a hole in the bottom of a battery. Check the electrolyte level in each of the cells - you could have a completely empty/dry cell in there...

Hope this helps.

RLW
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Old 08-29-2012, 10:25 AM   #7
simple man
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Default Re: Troubleshooting a Resistor

Check too that your wiper board linkage didn't get bent. If it doesn't give full movement to the wiper board, you won't get full power or speed.
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Old 08-29-2012, 11:03 AM   #8
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Default Re: Troubleshooting a Resistor

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Originally Posted by simple man View Post
Check too that your wiper board linkage didn't get bent. If it doesn't give full movement to the wiper board, you won't get full power or speed.
I didn't think about that, but it could easily cause his problem.

Good catch!

RLW
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Old 09-01-2012, 08:35 AM   #9
skeeter621
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Default Re: Troubleshooting a Resistor

Just getting around to taking some pictures.

Battery pack voltage equals 37.78 V. Individual battery voltages 6.27 V to 6.38 V.

Thanks,

Skeeter
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Old 09-01-2012, 08:54 AM   #10
rlw
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Default Re: Troubleshooting a Resistor

Ummmm....

That doesn't look like a resistor cart to me, it looks like a controller cart. Isn't that the controller to the right of the solenoid and pot box in the second photo?

Also, I'm not sure why you have a wire hanging off the FNR switch (red wire to the right of the key switch).

As a start, it looks like you should at least clean up the lugs on the power circuit -- the red wire going to the controller looks pretty badly corroded.

Since my experience is with my resistor cart, I probably won't be much help. JohnnieB/ScottyB will probably be along soon to lend some advice.

Sorry,

RLW
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