94 Marathon jerky at slow speed.

[kriegtb]

So I just completed my 94 Marathon project. 4" lift, flip flop seat, re-upholstered seats, 4 ga wires, front cowl with lights, diamond plate accessories, Ford Blue Flame paint. I actually bolted on all the accessories before stripping down for paint just to make sure everything fit. The cart ran fine and with the new cables, cart had good torque and ran smoothly topping out around 17mph.

I put it all back together and called the kids out for the first test drive. Hit the accelerator and it was very jerky (similar to the feeling of gas in a carburetor) to start. Once it gets going it smooths out. Now it tops out around 15-16mph.

Here is the before and after pics.

Any ideas?

[EZGO-MY-WALLET2]

no idea but I will tell you very nice job on the cart, looks great. Someone be along to help you soon I am sure. (bump)

[rabbitreborn]

can you post a pic of the guts of the cart so we know what components we are dealing with?

[kriegtb]

Here are a few pics of the electronics. I believe it has a Curtis 1204 controller. The motor model number is 5BC58JBS6132A.

I removed the F/R and cleaned it today. Still same problem. Just jerky at low speed and seems to have low torque, especially on slight grades. Checked speed with GPS today and looks to be around 15mph on flat surface but slows to 11-12 on slight grade. New batteries, 4 ga wires, 22" tires. No issues before I stripped the cart down. Removed the F/R and controller together without disconnecting wiring when I tore it down. The only thing I am worried about is that I pressure washed the body after stripping down and am wondering if water could have gotten into the motor.

[rabbitreborn]

ok everything looks wired correctly which leaves me with just a few questions....

have you checked the output of the pot box? Is it a smooth increase from 0-5k?

when you removed/replaced the wires going to the motor did you use 2 wrenches? I have seen studs spin and cause a similar issue.

Are you going to replace that solenoid? It is actually the wrong solenoid for the cart and COULD be the cause of your problem since it peaks at 200 AMPS and that controller looks like the 300 AMP controller that E-Z-GO used for a few years.

[kriegtb]

I did check the pot box. It does go from 0-6k. Hard to say how smoothly it moves through the range. I used my Fluke digitial meter which as a bar at the bottom and it seemed to be pretty smooth.

As for the solenoid, it is the same one that has been on the cart for years. This was my dad's cart before I got it. I had no issues before I took everything apart. Is there a way to identify the controller as a 300A? I dont rememeber seeing an ID tag but I wasn't looking for one either.

The motor stud could be an issue. I only used one wrench and I remember one or two of the studs moving. What does this mean and is it something I can repair?

Thanks for the help so far.

[kriegtb]

I forgot to mention that after about 20 minutes of cruising around my neighboorhood, the motor was very hot to the touch. I could not keep my hand on it.

If I replace the solenoid, do I need an HD type. I found a few in the $65-70 range. Does that seem reasonable?

[rabbitreborn]

Scotty has the solenoid you need, you can use a MZJ200 for this application

the range on the pot is not that bad so I wouldn't sweat that...

The controller should have a plate at the bottom that identifies it.

the motor has issues.... It should not be getting that hot and is the most likely culprit for your problem. yes, I have seem people repair their own motor stud issues before, but for the price that PlumQuick charges to do an awesome professional job, you are far better off sending the motor to them to have it rebuilt (plus you gain about 25% speed and torque from their work).

[kriegtb]

Thanks for the info. Does Scotty have a website to order from? I will get a price on the solenoid. I'll also pull the controller box out to verify the amperage.

I was thinking the motor could be the problem too. I will send a message through PQ's website to get the cost of a rebuild. Do you have a ball park of what that would cost?

[GreshamCA]

When I talked to Rick @PQ he said that a reman(Bandit) would be $225 but he has to have your motor and it would be a while as he doesn't have any EZGO series motors in stock. If I can ever get mine running I'm going to carry mine to him just for peace of mind.