Reconnected Club Car Engine - now won't go

[northon11]

We installed a 6" Jake Lift Kit on 2006 Club Car DS - 48 volt over the weekend. We disconnected the motor - labelling each connection carefully for reconnection, put everything back together but seem to have an issue now. The car will not go forward or in reverse and there appears to be smoke coming off the motor. Has anyone had a similar problem or experience? We still have the tires off and have it jacked up - but it will not go forward or into reverse?

Any advice would be greatly appreciated.

[rib33024]

Welcome to BGW

did you use two wrench's to remove the nuts on the battery cables on the motor ??, if you used one wrench you may have twisted the bolt in the motor and shorted it out,

[northon11]

Only on one of them did we use two. Is there any way to tell if it is shorted out? We narrowed the source of the smoke to be coming from what looks like the solenoid. It definitely has a burning plastic smell if it is connected. Doesn't appear to be any burn residue though.

[rib33024]

So your saying that one of the studs on the motor did spin when you removed the cable??

[northon11]

thank you for your help - no it didn't spin - they moved a bit but none of them actually spun. they weren't that tight to begin with when undoing them.

[northon11]

I should add - after the cables were reconnected, it initially went into reverse - but would not go into forward. We noticed the smell of the plastic, noticed smoke and undid the cables. After going back over and rechecking them and reconnecting them - it does not go into forward or reverse. As soon as it the smell of plastic was evident - we disconnected the battery cable again. If it is relevant, while this was going on - the battery charge light came on as well - not sure if possible the batteries are not charged enough?

[shadowman]

welcome.....if cart worked before you did the lift ....are you sure you lablede them right from the start? it has to be something you did........do you have the plastic soleniod? did you smell the controller? its a bad thing when you can smell it..............try charging it and see what happens.....................................

[shadowman]

welcome.....if cart worked before you did the lift ....are you sure you lablede them right from the start? it has to be something you did........do you have the plastic soleniod? did you smell the controller? its a bad thing when you can smell it..............try charging it and see what happens...........did you put it in tow?..........................

[northon11]

Originally Posted by shadowman

welcome.....if cart worked before you did the lift ....are you sure you lablede them right from the start? it has to be something you did........do you have the plastic soleniod? did you smell the controller? its a bad thing when you can smell it..............try charging it and see what happens...........did you put it in tow?..........................

Good morning and thank you! We were careful to label the connections - left front, left side, right front, right back, etc. - still have the tape in place as we haven't taken them off yet. We are thinking it is something we have done - just can't figure out what it is. We went back over the wires a third time to ensure they are all connected properly, tightly and snuggly. Where the smoke appears to be coming from is a small black box (when facing the motor at the rear) it is on the top left side. We were searching last night for a wiring diagram to confirm this box is the solenoid.

We were hesitant to charge it until we narrowed down what the issue is. It wasn't in tow - while we researched and read different threads before we began the installation - we missed the advice to put it in tow before disconnecting.

Currently one of the battery cables is off - if we put it in tow now - and reattach the cable - does that stop the power from going to the solenoid and controller?

Thanks again!

[shadowman]

its to late for that.....if the box your talking about is say 4 inches wide by 8 to 10 or so long with cables and wires going to it thats the controller and if so you smoked it.........soleniod has 2 big post with cables and a few small wires and 2 little bitty post with wires going to it......the area this box is in sounds like the controller.......you always have to PUT IT IN TOW before you work on it.......i,m thinking now you burnt up your controller and that would make sense.......................................