2003 txt stutter and smells hot

[mycamel]

My TXT has had a slight raspy noise coming from the rearend or motor for the past couple of months. I figured it was a rearend bearing going bad as was going to replace it on a rainy day.

We were out golfing today and noticed that the cart didn't seem to be getting up to speed and smelled hot right before I parked it. Full throttle made it seem worse and it would stutter when trying to take off from a dead start.

The batteries, cables, controller were all cool the touch. The motor was pretty hot, but this is the first time I crawled under the cart and felt the motor mid round. I'm not sure how hot it should normally be.

I think it is a brush issue with the motor (original motor from 2003). Looking for advice from others who have been in this boat...

Thanks for any input.

[LukeL]

It could be a number of things, including motor brushes. Did you check all the cables around the controller, motor, and FNR switch? Usually if it smells melted it is a cable. But there are always exceptions…

[mycamel]

I checked all the cables and connections by feeling each connection. They all felt cool. All connections are tight.

[JohnnieB]

The 17 year old motor more than likely needs new brushes and a new bearing as well as a thorough cleaning inside and out.

While you have the motor off, check the input gear for wear and replace input shaft bearings.

Change oil in differential also.

[mycamel]

Ok, I pulled the motor.
It is definitely the brushes. The question is, look at the commutator in the picture below. The brushes have worn a groove. I question if new brushes will save this motor. What do you experts think..?

My bad on this one...I should have been more proactive. My plan was to disassemble the cart one of these winters and re-wire and repair as needed. Since we have mild winters now, golfing takes me away from preventative maintenance.

BTW, I have a fairly new Alltrax controller and the batteries are only 2 years old.

[mycamel]

I went ahead and ordered a new motor. Buggies unlimited had a leap year 10% off sale that ends today. Rather than trying to save this motor, I'll let it RIP after 17 years of hard service.

I don't need a fancy high HP motor. Just one that will get me 36 holes on one charge.

Lesson learned on this one..