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Electric EZGO Electric EZ GO Marathon, Medalist, TXT and RXV. |
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08-29-2018, 08:58 AM | #21 |
Gone Wild
Join Date: Jul 2011
Location: Rhode Island
Posts: 489
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Re: Bad Boy Buggy problems.
Sorry, my season is in full swing so I havent been on much plus a daughter on the way, time seems to disappear.
I'll see what I can dig up. |
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08-29-2018, 11:20 AM | #22 |
Gone Wild
Join Date: Jul 2011
Location: Rhode Island
Posts: 489
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Re: Bad Boy Buggy problems.
For the BBB Classic
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08-29-2018, 11:23 AM | #23 |
Gone Wild
Join Date: Jul 2011
Location: Rhode Island
Posts: 489
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Re: Bad Boy Buggy problems.
From my notes from class years ago:
Bad Boy Sevcon controller Pin out voltages Pin # 1 -Vehicle harness wire color White or Gray/ Controller harness wire color Red-Controller power up circuit- BRV Pin #2 –Vehicle harness wire color Yellow with green stripe/ Controller harness wire color Black-Forward input-5 volts to ground circuit Pin #3-Vehilce harness wire color Orange/Controller harness wire color Brown-Reverse input-5 volts to ground circuit Pin #4-Vehicle harness wire color Blue/Controller harness wire color Light orange or peach-5 volt drops to 1 volt when the throttle pedal is depressed Pin #5-Vehicle harness wire color White with Black stripe/Controller harness wire color Dark Blue-5 volts with the key switch in the on position/ zero with key in the off position Pin#6-Vehicle harness wire color Black with White stripe/Controller harness wire color White-5 volts with the key switch in the on position/ zero with key in the off position Pin#7- Not Used Pin#8-Vehicle harness wire color Black with Red/Controller harness wire color Pink-Solenoid ground driver circuit-BRV when you reference to positive/Negative to ground circuit Pin#9- wire color Purple for Programming only Pin#10-Vehicle harness wire color Yellow with Brown Stripe/Controller harness wire color Yellow- .5 volts to 4.5 volts reads steady through the range as the throttle pedal is depressed Pin#11-Vehicle harness wire color Red with Tan Stripe/Controller harness wire color Light Green-4.5 volts to .5 volts reads steady through the range as the throttle pedal is depressed Pin#12-Vehicle harness wire color Red/ Controller harness wire color Gray- 12 volt circuit with the key switch turned to the on position. |
08-29-2018, 11:23 AM | #24 |
Gone Wild
Join Date: Jul 2011
Location: Rhode Island
Posts: 489
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Re: Bad Boy Buggy problems.
Flash Codes
1 Flash. Personality out of range. This is caused by one of the settings in the controller being set out of permissible range. The only way to correct this is to reprogram the controller with the newest software version utilizing the PcPak. Updating the controller software should solve this problem. This code can appear on one or both controllers at the same time. If the controller does not respond to reprogramming, please contact the service department at Bad Boy Buggies for further assistance. 2 Flash. Incorrect Startup Sequence. This is usually caused when either the directional switch on the dash is in forward or reverse when the key is switched on, or if the accelerator is depressed before the key is turned on. If a buggy starts off operating normal and then produces a 2 flash code during operation, typically it is because the controller has lost and then regained power. When the controller powered back up, it saw the direction switch engaged at power up and therefore produced a 2 flash fault. If this is happening, check the wire in the pin 1 location of the 12 pin controller plug on the wiring harness side. Check that it is secure in the plug. That wire should be either white or grey. If it checks ok at the plug, locate the same wire at the fuse box and check that it is tight there. Check that the connection is free of any corrosion. Check the fuse for being loose. Sometimes the prongs that hold the fuse can become loose and need to be squeezed together to hold the fuse more securely. If the problem is still present, remove the wire from the fuse box and place it on the same terminal as the green wire from the key switch. If doing this corrects the problem, replace the fuse box. If the problem is still present contact the service department at Bad Boy Buggies for further assistance. 3 Flash. MOSFET Short circuit. The first thing to do when you encounter a 3 flash is to connect the PcPak to the controller. If the status says mosfet short circuit, the controller needs to be replaced. A high resistance connection can also cause a 3 flash. This can be a loose connection or bad cable, but is very rare. If the 3 flash in on one controller it is a connection used only by that controller. If it is on both controllers, it is a connection shared by both controllers, such as the B+ cable from the Batteries to the line contactors. Or the B- cable from the batteries to the controllers. 4 Flash. Open circuit fault. This is almost always caused by a loose connection. The first thing to do is connect the PcPak to the controller. This will give you a better explanation of the fault code. A 4 flash is almost always caused by a loose connection. If you have a 4 flash check the following. Check ALL wires on the controller and the corresponding motor to make sure they are tight and free of any corrosion. If they are tight, tug on them to make sure the terminals are crimped on solidly. If that checks ok, remove the cup holder and make sure that all of the Phillips head screws in the fuse box are tight and free of any corrosion. If the prongs are tight, check for a bad fuse. If that checks ok, check the prongs that hold the fuses and make certain they are holding the fuses tightly. 99 times out of 100 one of those things is the cause of a 4 flash. A welded line contactor can also cause a four flash. To test the line contactor for being welded please refer to the instructional sheet on testing a line contactor. 5 Flash. Not Used. 6 Flash. Accelerator wire off fault. This often times a loose connection in the accelerator wiring. Check the four pin plugs in the accelerator wires to see if a pin has backed out or if the wire has loosened up in the pin itself. Also check in the accelerator wires for additional connections that could have possibly become loose. It is possible for someone to have snagged the accelerator wiring on debris and pulled a wire loose. If all of the wiring checks ok, it is possible that the accelerator is bad. To check this, connect to the controller with the PcPak. Look at the percentage of accl. Push. A faulty accelerator will show as being depressed when it is not. Replacement is the only option for a faulty accelerator. 7 Flash. Battery Voltage too high or low. You should never see this code with high voltage being the problem as it is almost impossible with our settings. If the battery voltage is lower than is required to operate the buggy it will trip into a 7 flash fault. It is possible for a faulty key switch or faulty fuse box to cause a 7 flash as well. If the batteries are charged and the buggy is giving you a 7 flash, test the voltage coming out of the key switch on the green wire. If it is lower than battery voltage replace the key switch. If the key switch checks ok, replace the fuse box. If the problem is still present contact the service department at Bad Boy Buggies for further assistance. 8 Flash. Over temperature. The controller has overheated and must cool back down to normal operating temperature before it will resume normal function. 9 Flash. Replace Controller 10 Flash. Replace Controller If you have a controller with a flash code not listed here, please contact the service department at Bad Boy Buggies (LOL) for further assistance. |
08-29-2018, 10:45 PM | #25 |
Not Yet Wild
Join Date: Aug 2018
Posts: 11
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Re: Bad Boy Buggy problems.
Titus, you are amazing. I was able to figure this thing out using your tips. I will do a complete write up so maybe someone else can benefit from my trial and error.
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09-25-2018, 10:13 PM | #26 |
Not Yet Wild
Join Date: Sep 2018
Location: Oklahoma
Posts: 7
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Re: Bad Boy Buggy problems.
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09-28-2018, 02:11 PM | #27 |
Not Yet Wild
Join Date: Sep 2013
Posts: 4
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Re: Bad Boy Buggy problems.
FF Titus: I have two Bad Boys a 2008 classic with two sevcon controllers both flashing 4 times. Also a 2015 Recoil is, left controller flashing code 12 and right controller flashing 72. Neither cart will move. Any troubleshooting info would be greatly appreciated.
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10-15-2018, 02:32 PM | #28 |
Not Yet Wild
Join Date: Oct 2018
Posts: 1
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Re: Bad Boy Buggy problems.
Where can I get a Accelerator pedal ? or does anyone have one for sale ? Thanks
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11-25-2018, 12:26 AM | #29 |
Not Yet Wild
Join Date: Nov 2018
Posts: 1
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Re: Bad Boy Buggy problems.
do you still have an accelerator assembly? I have a 2010 classic bad boy
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12-18-2018, 06:02 AM | #30 |
Not Yet Wild
Join Date: Dec 2018
Posts: 2
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Re: Bad Boy Buggy problems.
Do you have any for 2016 BBB Reciil Is
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