2003 DS 48V won't move after lift installed

[ospreybill]

Hello all, been on this site quite and bit and enjoy all the information. I installed a lift kit on my 03 48V DS and now it won't move. When I hit the accelerator pedal I hear two clicks from what I believe the solenoid, about a half second apart. The cart feels like it is trying to move but won't move under it's own power. I even pushed it a few feet but that didn't get it moving under it's own power either. Serial number is AQ0310-264138. I checked the batteries last night after a charge and had, if I remember correctly, 51.3v. I need to add that I had an issue with my floor jack so at one point during the install of the lift kit the rear axle had come down to the point that the cables to the motor were stretched and keeping the rear axle from spinning so it is likely that this is something I caused. What should I check next? Thank you for the help.

[Sergio]

Most likely either the F1 or the F2 Motor wires that use a quick connector came OFF the back of the Controller where they are plugged.

[mrgolf]

When the axle dropped it likely pulled wires loose on the controller. Take the cover off the controller and check the wires.


Edit I type too slow

[ospreybill]

Hi Sergio and thanks. I checked all plugs on the back of the motor and they are all connected.

[ospreybill]

I will check the wires at the controller end again and report back. Thank you.

[ospreybill]

From what I can tell, the cables look fine (see pics attached). I did jack up the rear of the cart and pressed the pedal and one of the wheels moved about half of a revolution but that was it. What should I check next? Thanks.

[Sergio]

You need to remove the weather cover so You can see the Controller connections.

The Blue and the Red motor wires use quick connectors on the controller and can easily become disconnected.

[Fairtax4me]

A2 cable end on the motor is fried too. Needs to have the end cut off and cut the wire back an inch or so to get to clean copper, then crimp or solder a new 6ga terminal with 5/16 hole.
You’ll want to spray the motor stud with penetrating oil and let it soak, and use a wrench on the lower stud nut to make sure it doesn’t spin the stud when removing the upper nut.

[mrgolf]

Originally Posted by Fairtax4me

A2 cable end on the motor is fried too. Needs to have the end cut off and cut the wire back an inch or so to get to clean copper, then crimp or solder a new 6ga terminal with 5/16 hole.
You’ll want to spray the motor stud with penetrating oil and let it soak, and use a wrench on the lower stud nut to make sure it doesn’t spin the stud when removing the upper nut.

Looks like that stud was broken also.

[ospreybill]

The blue wire was disconnected under the weather cover so that was it. As far as the A2 end that is fried, I will try to get to that this weekend. I suppose I should probably get someone to replace that stud as well. Thanks a lot to you guys for helping me on this.