03 txt quit

[ajm555]

Hello all, I bought a 2003 TXT 36 V for the wife to get around with. It seemed to run just fine when I gave it to her. She drove it around the property one time (approx 1/2 mile) and it quit. It smelled of something burning and upon inspection the battery cables were hot to the touch as well as some of the other cables. I got it to my shop and found the F/R handle would not go into reverse without forcing it. The solenoid clicks when depressing the accelerator but nothing else. Batteries are at 38+ volts. Where do I start to get it running again? Thanks.

[Babyboy70363]

Heres a great place to start!

http://www.cartsunlimited.net/troubleshooting-tips.html

[orangeman6]

http://www.buggiesgonewild.com/elect...nder-seat.html

It sounds like you’ve got a series cart. Check out the thread above. It’s another guy having a problem with his f/r. I’m not knowledgeable enough to know if a bad f/r could cause heat in the battery cables, but it does sound like your f/r is bad. Probably not a bad idea to check all high voltage cables for correct tightness and corrosion.

If you’re not already aware, that f/r switch has contacts that have to make a solid connection when it’s rotated into position for forward or reverse. It’s a prevalent problem in the series carts. I know I’ve read about guys adjusting, re-grinding contacts, etc, but for my .02 opinion I would change that thing out to one of Scotty b’s contactors. You get rid of a problem part in the cart, plus you get a much easier method of switching directions. Of course, you might just need to adjust yours, but I’d switch it out anyway.

http://www.cartsunlimited.net/reversing-contactors.html

[yurtle]

Any cable that gets hot should be replaced. In fact, if more than one is bad, the others are likely suspect. I'd consider replacing ALL of them.

As to the FNR, if it got hot enough to smell, you've likely caused irreparable damage, and I'd replace it as well.

[scottyb]

The reversing contactor upgrade and conversion to rocker switch F&R is a real plus for wives who do not want to mess with a funky F&R lever.

[ajm555]

Thanks for the info. Upon close inspection I found two cables to the F&R that were just hanging by a thread. In fact one came loose when I tugged on it. Will replace the F&R tomorrow. Will post results.

[ajm555]

Thanks for all the help guys. I replaced the F&R, tightened and installed new cable ends where needed. It runs fine now. Again thanks.

[yurtle]

After a long ride, I'd lick my finger (so as not to burn it) and touch each and every cable end to make sure there are no more "hot spots".

[ajm555]

Thanks Turtle, After a short ride up and down hills I stopped and did as you suggested and found one cable to be hot. It is the cable from the battery to the controller. Although it runs well it still is weak uphill. Any suggestions to increase torque?