91CC Resistor cart sparking!

[BRS]

My 91CC resistor cart sparks/arcs everytime the f/r switch is put in gear. I replaced the switch and solenoid and it's still doing it. If left in a partial forward position it will spark and catch fire. You can see it spark when rotating the f/r handle. What do you make of it. Everything on cart is stock.

[shadowman]

let me think on this, i ran into it once before but at the minute can,t recall the fix............................................... .

[jdunmyer]

The only way the F/R switch will spark is if there's power going to it. (Duh!) There should be NO power to that switch if the solenoid is de-energized and not shorted out.

1. Does the solenoid click when you press the pedal down, then click 'off' when you release it?

If it clicks as it should, continue to Step Two:

2. Is there power to both sides (big terminals) of the solenoid: a. when the pedal is 'up' (BAD)? Or only when the pedal is 'down' (GOOD)?

There also is a micro switch on the F/R switch that prevents the solenoid from being energized unless the switch is moved all the way to either Forward or Reverse, but that is probably not the problem.