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Old 07-26-2022, 04:10 PM   #1
jesseldossey
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Join Date: Jul 2022
Posts: 1
Default Star Classic massive mechanical/electrical problem. Please help

I have a star classic 48-4+2 golf cart. Curtis 1268 controller, 48v ADC motor. In the beginning it wouldnít go past 1.3 miles and hour and violently shakes in the rear end. Gave it to a mechanic and all he did was put water in the bats. Got it back, drove fine for 30 seconds then completely lost wheel power. Pulled off to the side and turned off and on. Then it ran great for about a mile until it went back to its shuddering slow creeping forward speed. I changed the speed sensor and magnet, solenoid, cleaning battery terminals and connects thoroughly, speed controller is getting adequate voltage and not throwing codes. Each battery is good, pack voltage with and without load is correct. I jacked it up the shuddering noise is coming from the differential/motor area. With the cart off, spinning the wheel feels like itís catching something and has a grinding sound. Also with the pedal all the way down, on top of the creeping slow speed, the wheel has almost no resistance, I can even hold it in place and stop it from spinning. When I hold it in place it also feels like itís catching something like a gear, every inch or two of spinning. Also today the charger had lights come on and after calling the manufacturer they say itís battery issues. Gonna leave it on the charger overnight. Could all this be battery problems? Is the differential thing normal? Please help cause itís driving me nuts. Thanks
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Old 07-30-2022, 09:39 AM   #2
hardhouseinc
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Join Date: May 2022
Posts: 78
Default Re: Star Classic massive mechanical/electrical problem. Please help

if its the same motor as in mine its likely the brushes are froze up and are arching like hell and not making a connection.
These motors have a bad designed brush box and they create corrosion that fuses to the brushes. Then they stop working if they burn up the brushes. if it hasn't gone too far just replace the brushes and clean up the brush box. while you have it apart change the bearing its easy and like 10$

I've done two of these motors now and the one in my club car was the same.
One brush had self destructed and the wire arched and fused itself to the brush box then blew a hole in it. IDK how it was running at all on three brushes. But had the same issue. was very erratic and would barely go 3mph after much use at all.

Pull the body and the motor and check out the brushes. They are probably stuck or worse. As long as it hasn't chewed up the armature you should be fine. just polish it with some emery cloth and change the brushes and bearing.

put up some pics and I can see if its the same motor I just rebuilt.
I can show you what cheaper parts to use.
The star parts are stupid and just overpriced of the same ones that go in my 2014 club car.

Fix it and sell the pofs I hate star carts.
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