Hot plastic smell??

Silverstreak · 03-31-2012, 08:01 PM

I ride my cart through our fields and woods. I usually ride pretty slow, looking at nature. This past week, I noticed a strange smell. My husband said he's always smelled it, but it was new to me. Today my son said it smelled like hot plastic to him. I felt the wires, the batteries, the controller cover and the box behind it (motor??) and only the controller cover felt just a tiny bit warm.

Is there something I should be looking for? Should I be worried? I definitely need to buy the right fire extinguisher this week. (which one again? I think its the marine one?).
Thanks.

rib33024 · 03-31-2012, 08:15 PM

I guess this is a 06 txt series? if it is , check all your cable ends and make sure they are tight and not burnt looking, check the back of the F/R switch where the cables hook up and make sure there tight, look at the F/R close and see if anything is melted or burnt, check the cables at the motor to, if you don't seee anything, remove the cover on the controller and check all cables and the solenoid

scottyb · 03-31-2012, 09:05 PM

Check the F&R for signs of heat. It is common to see melted plastic around the housing at the large terminal studs. If that's the case it leave you in the lurch soon.

Silverstreak · 04-01-2012, 08:22 AM

Thanks rib and scottyb.

To check the terminal studs on the F/R, I need to remove the cover, right?
Yes, I have a lifted 2006 TXT series.
Are some of those connections to you mentioned underneath the cart or are they all accessible from under the seat?

scottyb · 04-01-2012, 08:40 AM

Yes under the F&R cover.

Silverstreak · 04-01-2012, 11:28 AM

Should I disconnect some cable to the batteries when checking out the controller and the motor?

simple man · 04-01-2012, 08:59 PM

If your cart has a " tow - run " switch, place it in tow and disconnect the + cable that goes to the solenoid before you do any work on the electrical system!

Reconnect the + cable and then put the switch to run when you are finished your work.

To do tests of the controller and motor that won't involve disconnecting the batteries, leave the switch in the run position.

rib33024 · 04-02-2012, 02:52 AM

Quote:

Originally Posted by Silverstreak

Thanks rib and scottyb.

To check the terminal studs on the F/R, I need to remove the cover, right?

Yes

Yes, I have a lifted 2006 TXT series.

Are some of those connections to you mentioned underneath the cart or are they all accessible from under the seat?

Yes under the seat

Silverstreak · 04-02-2012, 11:44 AM

Thanks Rib.
Simpleman........I don't have a run/tow switch. What should I do then?

rib33024 · 04-02-2012, 01:04 PM

you don't have to disconnect any thing to see if there is some thing wrong, just look and if it is bad, now if it is melted at the F/R then disconnect the main pos+ and neg- remember where the cables go if you take any loose/take some pics before taking anything loose, now if the F/R is good? ( i think the F/R will be the problem), if the F/R is good, remove the POS battery cable and the neg cable tape up the ends of the cables/ no sparks, remove the cover on the controller, there's four bolts the two on the bottom are a pain to get to, inspect all the cable ends on the controller, and the solenoid, did you ever up grade the cables? with the lift and big tires your pulling alot of amps, if you take any cables loose from the motor use two wrenches, one to hold the nut under the cable and one for the nut on top of the cable DO NOT let the stud turn in the motor IF you get that far, be careful

03-31-2012, 08:01 PM	#1
Silverstreak Gone Wild Join Date: Sep 2011 Location: Midwest Posts: 385	Hot plastic smell?? I ride my cart through our fields and woods. I usually ride pretty slow, looking at nature. This past week, I noticed a strange smell. My husband said he's always smelled it, but it was new to me. Today my son said it smelled like hot plastic to him. I felt the wires, the batteries, the controller cover and the box behind it (motor??) and only the controller cover felt just a tiny bit warm. Is there something I should be looking for? Should I be worried? I definitely need to buy the right fire extinguisher this week. (which one again? I think its the marine one?). Thanks.

03-31-2012, 08:15 PM	#2
rib33024 ...................... Join Date: Apr 2009 Location: FT Lauderdale FL. Posts: 16,416	Re: Hot plastic smell?? I guess this is a 06 txt series? if it is , check all your cable ends and make sure they are tight and not burnt looking, check the back of the F/R switch where the cables hook up and make sure there tight, look at the F/R close and see if anything is melted or burnt, check the cables at the motor to, if you don't seee anything, remove the cover on the controller and check all cables and the solenoid

03-31-2012, 09:05 PM	#3
scottyb Happy Carting Join Date: Dec 2007 Location: Southern California Posts: 73,418	Re: Hot plastic smell?? Check the F&R for signs of heat. It is common to see melted plastic around the housing at the large terminal studs. If that's the case it leave you in the lurch soon.

04-01-2012, 08:22 AM	#4
Silverstreak Gone Wild Join Date: Sep 2011 Location: Midwest Posts: 385	Re: Hot plastic smell?? Thanks rib and scottyb. To check the terminal studs on the F/R, I need to remove the cover, right? Yes, I have a lifted 2006 TXT series. Are some of those connections to you mentioned underneath the cart or are they all accessible from under the seat?

04-01-2012, 08:40 AM	#5
scottyb Happy Carting Join Date: Dec 2007 Location: Southern California Posts: 73,418	Re: Hot plastic smell?? Yes under the F&R cover.

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04-01-2012, 11:28 AM	#6
Silverstreak Gone Wild Join Date: Sep 2011 Location: Midwest Posts: 385	Re: Hot plastic smell?? Should I disconnect some cable to the batteries when checking out the controller and the motor?

04-01-2012, 08:59 PM	#7
simple man Gone Wild Join Date: Aug 2011 Location: Bunnell, Florida Posts: 2,408	Re: Hot plastic smell?? If your cart has a " tow - run " switch, place it in tow and disconnect the + cable that goes to the solenoid before you do any work on the electrical system! Reconnect the + cable and then put the switch to run when you are finished your work. To do tests of the controller and motor that won't involve disconnecting the batteries, leave the switch in the run position.

04-02-2012, 11:44 AM	#9
Silverstreak Gone Wild Join Date: Sep 2011 Location: Midwest Posts: 385	Re: Hot plastic smell?? Thanks Rib. Simpleman........I don't have a run/tow switch. What should I do then?

04-02-2012, 01:04 PM	#10
rib33024 ...................... Join Date: Apr 2009 Location: FT Lauderdale FL. Posts: 16,416	Re: Hot plastic smell?? you don't have to disconnect any thing to see if there is some thing wrong, just look and if it is bad, now if it is melted at the F/R then disconnect the main pos+ and neg- remember where the cables go if you take any loose/take some pics before taking anything loose, now if the F/R is good? ( i think the F/R will be the problem), if the F/R is good, remove the POS battery cable and the neg cable tape up the ends of the cables/ no sparks, remove the cover on the controller, there's four bolts the two on the bottom are a pain to get to, inspect all the cable ends on the controller, and the solenoid, did you ever up grade the cables? with the lift and big tires your pulling alot of amps, if you take any cables loose from the motor use two wrenches, one to hold the nut under the cable and one for the nut on top of the cable DO NOT let the stud turn in the motor IF you get that far, be careful

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