Bad Boy Buggy problems.

[FF Titus]

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.

[FF Titus]

For the BBB Classic

[FF Titus]

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.

[FF Titus]

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.

[Finmad]

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.

[Medic5561]

Originally Posted by tonymac01

im parting out 2008 bad boy buggie because i just dont have the time to mess with it anymore anyone need motors, controllers, wheels, tires, parts.....................................

Do you still have it?

[Pat_3647]

Originally Posted by FF Titus

For the BBB Classic

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.

[Doogy65501]

Where can I get a Accelerator pedal ? or does anyone have one for sale ? Thanks

[GABE]

do you still have an accelerator assembly? I have a 2010 classic bad boy

[PKT1283]

Do you have any for 2016 BBB Reciil Is