[joesnuffy]

Need some help please.

Got a EZ GO golf cart the model is 2000 up when I try and attach the positive lead that goes to the batteries it makes a violent arc/spark so much so it can not be connected. I am attaching the wiring diagram I located and a pic of the actual speed motor controller. I tested everything I thought it could be to narrow it down to the speed motor controller. The golf cart is my neighbors and they only use it when they are in Florida this year they connected the batteries before I got there and I think they connected the positive and negative leads backwards.

I did test the motor jumping S1 to A2 then connecting 18 volts positive to S2 and 18 volts negative to A1 and the motor ran smoothly and quietly. I had the golf cart jacked up in the rear to prevent it from moving.

I also tested the key switch on and off function using continuity where it plugs into the speed controller, I also tested the fwd/reverse switch using continuity to where it plugs into speed controller, and the the pedal switch where it plugs into the controller on that test I didn't get any varied resistance when I checked between the black and white wire that plug into the controller. I also jumped the solenoid to make sure it was clicking and making connection as it should when power is applied. The battery charger is also working as it should and the batteries are fully charged. I also tested the tow switch and it is working as it should also. I also tested the reed switch and it is working. I don't know how to test the motor speed sensor or if it would have any bearing on this.

Any help would be appreciated. I am not a golf cart mechanic but it is fairly simple wiring other than what is inside the motor controller. I think it might be something inside there possibly a relay that is frozen from where it was connected backwards?

Thanks for the help and forum.

Joe