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Old 10-16-2012, 03:40 PM   #1
Silverstreak
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Default Question about F/R assembly and corroded wire

Just to remind you, I don't know much about these things....and I don't have the body that will allow me to fix much.

Whenever we take a long, slow ride through the woods, we start smelling something like plastic or wax. I used to think that meant my contacts in the F/R switch assembly weren't making good contact, because sometimes my reverse doesn't engage. So I use dielectric grease on it and it usually works better. (Is it normal for the housing to get a bit warm after use?)

Today, while applying the grease, I noticed that one of the wires going from the switch to wherever it goes has about 1/3 of an inch of the covering off it where it attaches to the switch. Plus, there's what looks like green crumbly residue on the wires. It felt as though that bolt/screw was loose. I tried to tighten it, but it just doesn't tighten. Its not real lose, just wobbly. The wire connection to the bolt seems tight.
So with my very limited knowledge, I'm thinking the burning of the wire covering might be what we're smelling. I tried not to touch that wire much, since the covering just starts flaking off by the connection.
Here's the problem: I found an EZGO service place, but they said they would probably have to keep it for a week to 10 days, since I need a number of things worked on.
I really depend on this cart to get our large property ready for winter. So I'm really trying to make it to November before I call them. Is there anything I can do for this wire in the meantime? Should I flake off that green mineral stuff and wrap that little section of wire with electrical tape? I'm thinking the entire bolt on the switch is loose and has a problem. But I just really need to get this cart through the next few weeks.
Am I risking something bad happening, if I just keep using it until it gets worse and maybe won't run?
I appreciate any advice.
Thanks!
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Old 10-16-2012, 03:48 PM   #2
scottyb
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Default Re: Question about F/R assembly and corroded wire

You have probably gone as far as you should with the cart. It has given you lots of warnings and the F&R is going to fail. Tightening the loose stud only pulls it deeper into the melted housing and reduces the chance for a solid contact. You will need a new HD F&R asap.
According to law it will fail when you are the farthest from the house or barn close to dark.
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Old 10-16-2012, 03:56 PM   #3
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Default Re: Question about F/R assembly and corroded wire

Thanks Scotty. Is there anything at all I can do to give me just a wee bit more time? Is there any way of being gentle on it?? Just use it as little as possible? The cart really serves as my legs and I won't be able to do much without it.
But you're right........it will quit at the worst place and time, I'm sure.
At least I found a place to work on it. It will need lots of work probably..........springs, brakes, and now the F/R. It needs about as much work as I do! :)
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Old 10-16-2012, 04:21 PM   #4
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Default Re: Question about F/R assembly and corroded wire

Put it in gear, tighten up the 9/16ths nut on the center shaft, all the way, and do not shift it any more... live with it in gear, hopefully forward, the more you shift it the more chances there are for misalignment. Also stay away from any long slow riding, any unnecessary riding, any steep hill riding.
Good luck
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Old 10-16-2012, 04:35 PM   #5
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Default Re: Question about F/R assembly and corroded wire

Thanks scotty.

Does that mean I shouldn't even put it in neutral at night, when its charging?
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Old 10-16-2012, 04:46 PM   #6
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Default Re: Question about F/R assembly and corroded wire

Yes, that's what he means. He's telling you to lock the contacts together so they do not move. IMO, springs and brakes can wait until you're ready to put the cart up. That switch needs fixed immediately if not sooner. It takes less than an hour to replace one. Have the dealer get a stock one if you don't have the time to wait for a good one from Scotty.
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Old 10-16-2012, 04:50 PM   #7
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Default Re: Question about F/R assembly and corroded wire

Thanks Kab,
If the one wire from the middle bolt is deteriorating at the end, will that need completely replaced or will they just fix the end of it?
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Old 10-16-2012, 06:48 PM   #8
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Default Re: Question about F/R assembly and corroded wire

They can fix the end of it but it sounds to me like you need a new cable set. Ask your shop if they will install your parts and Call me to get a cable set and F&R delivered ASAP.
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