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Old 06-30-2014, 03:55 PM   #11
yurtle
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Default Re: Intermitent Forward Reverse Problem

I'd look there for a loose connection. The ring terminal may be bad. I take it you are flicking the wire and not the actual solenoid?
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Old 07-01-2014, 06:43 AM   #12
JohnnieB
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Default Re: Intermitent Forward Reverse Problem

Connect your voltmeter's negative test lead to the battery pack's main negative terminal and its positive test lead to the solenoid's small terminal with two red wires attached.

With keyswitch ON and either F or R selected, you should read battery pack voltage when pedal is pressed.

If not, trace the circuit highlighted in Red on the schematic I attached to my post#2.
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Old 07-01-2014, 06:58 AM   #13
yurtle
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Default Re: Intermitent Forward Reverse Problem

When you say there is a black box covering the wires, you're probably referring to the cover. You'll need to remove the cover to troubleshoot. It's held in place by bolts threaded into the aluminum heat-sink, so if some of them don't easily loosen, you may need to let them soak in penetrating oil. You may still break a few, but that's no big deal, as long as you have enough to hold it in place.
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Old 07-01-2014, 09:59 AM   #14
crachic
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Default Re: Intermitent Forward Reverse Problem

Thanks yurlte and JohnnieB. I will try those items.

And yes the black box is the cover.

The cart is at my campsite so it will be a few days before I can try this. I will let you know what I find out.

Chad
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Old 07-01-2014, 10:19 AM   #15
crachic
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Default Re: Intermitent Forward Reverse Problem

yurtle,

Yes, I am flicking the wires, not the solenoid.

Actually I am flicking a plastic clip connector that has wires coming in on both ends. I have not looked at it and traced it back yet as to where the wires go but it is a clip.

I am not sure that helps at all but that is a little more info.

Chad
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Old 07-01-2014, 10:48 AM   #16
yurtle
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Default Re: Intermitent Forward Reverse Problem

There is a 4 wire MOLEX connector on many carts that is often problematic. One side goes to the throttle box, located on the floor, on the driver's side.
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Old 07-01-2014, 10:52 AM   #17
crachic
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Default Re: Intermitent Forward Reverse Problem

That is where I think my problem is. If I can confirm this, what is the proper way to fix it?
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Old 07-01-2014, 11:01 AM   #18
yurtle
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Default Re: Intermitent Forward Reverse Problem

Best way is to simply eliminate the plug. I don't see that it really serves a purpose, as there are spade connectors inside the throttle box.

I still have to unplug/replug mine every couple of months, as I haven't gotten around to fixing it. Soldering, or wire nuts would both work.

Mark the wires, if they aren't the same colors on both sides of the plug.
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Old 07-01-2014, 11:05 AM   #19
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Default Re: Intermitent Forward Reverse Problem

You may have luck spraying contact cleaner inside and unplug/replug several times. I did this and used a small screwdriver to attempt to tighten up the female ends. It helped, but didn't completely eliminate the problem.
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Old 07-01-2014, 11:13 AM   #20
yurtle
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Default Re: Intermitent Forward Reverse Problem

I've had pretty good luck with some MOLEX plugs, where the male and female metal connectors had become loose inside the plastic plugs, even when they are snapped together. I would push the male and female wires toward each other, one wire at a time. Works good for stationary equipment, but a buggy bounces around quite a bit, so it may not be a permanent solution.
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