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Electric EZGO Electric EZ GO Marathon, Medalist, TXT and RXV.



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Old 08-09-2014, 10:01 AM   #11
BigWes
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Default Re: Upgraded Contr / Solenoid / FR - HUGE SPARK! HELP

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Originally Posted by scottyb View Post
I see that pic of the cable end now ....... you have a dead short someplace. Check each cable -#1 thru 8 one at a time. Make sure no exposed ends are touching any metal other than the terminal they are attached to .
What is a dead short? is it metal touching metal some place it shouldn't?
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Old 08-09-2014, 10:09 AM   #12
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Default Re: Upgraded Contr / Solenoid / FR - HUGE SPARK! HELP

Ok, so I looked as closely as I could. It is possible that the connections from the small terminals on the Solenoid could have been laying on the metal for the larger terminals. I really couldn't bend my neck that far to see underneath them, but they were very close, on both sides, so I bent them up. I did not try to reconnect the batteries yet. do you think that could have been the problem?
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Old 08-09-2014, 10:09 AM   #13
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Default Re: Upgraded Contr / Solenoid / FR - HUGE SPARK! HELP

Could be that or a cable going to the wrong place? The final connection shown at battery B- there was + to - (that's a dead short)

So you have (+) at the controller B- or something ?
Hard to see it from the pics - But somewhere a cable is not like the diagram since we know the motor works okay - we can rule out a motor short... unless the motor terminals spun when you installed the cables.
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Old 08-09-2014, 10:13 AM   #14
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Default Re: Upgraded Contr / Solenoid / FR - HUGE SPARK! HELP

Ok, you just mentioned the motor terminals spinning. I just remembered that this did happen a very small amount.

When I was disconnecting the old cable from the A1 post, it spun, but not even 1/4 turn. As soon as it moved, I stopped and lubed it. I didn't have a wrench that was skinny enough to get on the bottom nut. After I let the lube sit for a few minutes, I was able to loosen the top nut without any more movement. Did I ruin the motor?
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Old 08-09-2014, 10:32 AM   #15
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Default Re: Upgraded Contr / Solenoid / FR - HUGE SPARK! HELP

I think it may have been the small wires from the solenoid touching the large terminal metal. I tried connecting the battery again and no spark! However, I'm unable to get the nut to screw on to the battery post that sparked. It is a little deformed at the top. If I was able to cut that small deformed portion off the post, would that hurt anything?
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Old 08-09-2014, 10:33 AM   #16
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Default Re: Upgraded Contr / Solenoid / FR - HUGE SPARK! HELP

You can test for a short in the motor with your multimeter. Put it on continuity. You should have continuity between A1 and A2 and again between S1 and S2 no continuity between any A and any S terminal.
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Old 08-09-2014, 10:55 AM   #17
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Default Re: Upgraded Contr / Solenoid / FR - HUGE SPARK! HELP

Woo Hoo! It's alive! Thanks Scotty, for the help. Now all I have to connect is the battery gauge and I'm in business.
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Old 08-09-2014, 11:17 AM   #18
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Default Re: Upgraded Contr / Solenoid / FR - HUGE SPARK! HELP

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Woo Hoo! It's alive! Thanks Scotty, for the help. Now all I have to connect is the battery gauge and I'm in business.
Phew! I Am relieved with you Brother. What was it?
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Old 08-09-2014, 12:34 PM   #19
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Default Re: Upgraded Contr / Solenoid / FR - HUGE SPARK! HELP

It must have been the terminals that connect the small wires on the solenoid touching the metal for the large wires next to it. I couldn't really see but they looked like they were very close. so I bent them away from each other and voila. So I connected everything and it lives!
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Old 08-09-2014, 02:05 PM   #20
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Default Re: Upgraded Contr / Solenoid / FR - HUGE SPARK! HELP

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It must have been the terminals that connect the small wires on the solenoid touching the metal for the large wires next to it. I couldn't really see but they looked like they were very close. so I bent them away from each other and voila. So I connected everything and it lives!
I looked at that in one of the pics but after a second look I thought it was clear.
Well I'm glad you found it. Enjoy the ride
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