Kinetek AC Controller on a Club Car DS

[Role]

I've got a Club Car DS 48 Volt with a Kinetek AC controller and AC motor.
Never seen this setup before and I have a feeling it's about to be a nightmare to figure what's wrong with it.

Problems/Symptoms:
1. Won't hardly go in reverse, 1-2mph
2. Solenoid won't always audibly click upon turning key on, you have to Ren off and then on sometimes 3 or 4 times before you hear it click.
3. Going forward it will move forward, as it accelerates from a stop it will shimmy and then go normal into a sprint and then lock up the rear wheels as the pedal becomes fully depressed.

Model controller: KCCA0021-D

I've never seen this setup before on a club car chassis with this specific brand controller.
The AC motor looks similar to an ezgo RXV AC motor but without the parking brake sitting off the side of it, which was my initial thought as to what it could be (brake seized up) but this setup utilizes the original drum brakes.

Throttle box is not an MCOR obviously, it's a Curtis throttle box model FP.6D

Need to get this thing operating normal.
There apparently is a USB host software that can be used via USB plug, but I don't see any plugs on the controller to hook up to.

Any help is much appreciated!

Attached some photos below

[Role]

Pic 2

[Role]

Pic 3

[Role]

Pic 4

[NoleFan4Ever]

Never seen that set-up either, but it sure sounds like an EMCOR issue except the part of locking up the wheels(?) The controller would be my next suspect as both of those inputs are needed for the contactor on the solenoid to close (click).

Others may have seen this and might chime in.

[greg-g]

I took a quick look at thespec sheet for your controller low battery voltage of 38 volts, key switch input, 1 phase of the motor and a number of other things could cause similar problems take a look at the spec sheet online you can program I think up to 6 inputs four different things six or eight outputs

[greg-g]

Main solenoid dropping out there's a seat switch both forward reverse such as making contact at the same time throttle switch dropping out it does have regen braking

[cgtech]

Kinnetek OH GOD, RUN! I messed with one forever, called the company, they said it's an internal problem, send it in. That was years ago, never seen controller again. Couldnt ever get calls returned. That Star cart is now stripped in the junk yard!

[Role]

Update***
Rear Transaxle was a goner from the jerking and slamming to a stop from a sprint from the irratic behavior of the cart. I pulled the Curtis pot box off, checked the internal components and microswitch.

Replaced the solenoid, pulled the dash and wiring, recrimped questionable wires, took motor off and replaced entire transaxle.

Still doing it!
Found the Kinetek schematic for the controller and motor wiring along with the LCD display. Everything is where it should be, clean, and good connections.

Boils down to... the controller or motor, or both!
So I'm probably just going to trash the controller and trash the motor and start fresh with a reputable brand controller and motor that can utilize the same Curtis FP.6D potentiometer and be done with it.

Any recommendations for another AC conversion kit for this 2004 Club Car DS?
AND / OR
A DC setup with a beefy controller and a high speed motor - an Assassin motor or something along those lines?
Suggestions?

[Role]

Originally Posted by cgtech

Kinnetek OH GOD, RUN! I messed with one forever, called the company, they said it's an internal problem, send it in. That was years ago, never seen controller again. Couldnt ever get calls returned. That Star cart is now stripped in the junk yard!

CGTECH - "RUN" ... my thoughts exactly