Electrical short to DS Chassis

[Frizbgolf]

I once had one of the wires coming from my forward/reverse switch get caught between the frame and the battery and it rubbed a hole in the insulation and shorted out to the frame, was getting something like what your describing but only when in reverse.

[Morjus]

At last, a place to look. Thanks!

[Sergio]

Did You measure the voltage at the controller body when it is separated from the cart frame?

Does the voltage change when the key switch is ON and motor running?

You also need to put a load in parallel with the meter to make sure it is not just "coupled voltage" you are reading.

Just find an incandescent 60w light bulb or any other low resistance device and connect it between pack negative and the frame.

The circuit board is on the top on those controllers and the capacitors tops are towards the bottom, so it is possible that screw perforated one of the filter capacitors.

[swm63]

Worn motors filled with conductive dust have also been known to pass phantom voltage... Just a thought.

[Mooncarter]

Morjus, after everything you have tried, I think you have your answer, (at least to pack voltage on frame) the controller must be leaking voltage to the frame. Even if you were able to somehow isolate it, I would not trust that controller. I can't think of anything other than replacing it, or at a minimum checking it with another controller.

[Raystar57]

Originally Posted by Morjus

Bloody electrical poltergeist, I think.
I've re-mounted the Controller, but yellow not yet connected to solenoid. Still 10V
Disconnected positive lead to solenoid from battery stack- still voltage
Disconnected the other three small wires from positive terminals- STILL 7.2V
...but at least it's reducing???....

If all these leads are disconnected from the solenoid the only wire I would suspect
is the red wire from the battery pack to the charger port somehow.
This would have the pack voltage on it.
Charger port mounts to the plastic body so I don't see how that would conduct to the frame...
Remove that wire from the pack and see what you get.
The only other source wire is the main cable to the solenoid but you disconnected that and still have voltage...

Has to be from one of those two wires to the frame somehow.
Or a battery acid leak to the frame from the batteries but you said they are new and clean.