2002 ds IQ won't go but has solenoid click.

GolfinDoc · 03-22-2021, 04:57 PM

02 48V ds IQ ( fnr rocker switch)
My kids were riding the cart a few weeks ago and it died shortly after leaving our house. They said the cart was acting strange and seemed to strain to get to the end of the driveway before it died completely. The cart has new batteries and a new charger so we knew it wasn't a charging issue. Upon inspection there was a wire loose at the motor (the terminal on the left if looking at it from the front of the motor). The motor terminal is severely corroded and the prior owner had used a hose clamp to force the wire on the terminal. I replaced the hose clamp with a proper ring-style connector and connected that to the terminal as best I could. (I will try to post a picture later). While the cart was up on jack stands I tested the new connection and when the pedal was pressed the wheels spun so I was satisfied that the fix worked.
Unfortunately, now when you press the go pedal, the solenoid clicks and you can feel the cart begin to move, but it won't actually go anywhere. In both forward and reverse, there is a click from the solenoid and a "pull" to the rear, but the cart won't actually move.
The cart rolls fine without the pedal pressed, so I know it is not an issue with over-tightened brakes restricting the wheel or any other kind of mechanical binding like that. This leads me to think that the issue is likely with the controller, but my mechanic skills are generally limited to things with gas tanks and I admit that I am a bit out of my element here.
Where should I go from here?

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WalterM6 · 03-22-2021, 08:59 PM

My guess is that there is still something wrong with the motor. Connect your ohmmeter between A1 & A2 you should read low ohms in the range of 1 to 2 ohms. Next measure between F1 & F2. You should get the same results. Then measure between each terminal and the case, you shouldn't have any reading. Theory is if the solenoid is closing that means the controller is telling the cart to run. And it has to be the motor, solenoid or cables. Another theory is you may have shorted the controller if you didn't disconnect the battery when you repaired the cable. Do you remember making any sparks?

GolfinDoc · 03-25-2021, 02:57 PM

Quote:

Originally Posted by WalterM6

Another theory is you may have shorted the controller if you didn't disconnect the battery when you repaired the cable. Do you remember making any sparks?

I disconnected the batteries while I was fixing the cable, but then after I reconnected the batteries I dropped a wrench while replacing the access panel and it hit the two posts on the motor making a pretty good spark. Does that mean I killed the controller?

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WalterM6 · 03-27-2021, 07:00 PM

GolfinDoc · 03-29-2021, 07:04 PM

Yikes! That was not what I was hoping to hear. So, my next question would be recommendations for a new controller. I have no interest in trying to speed up the cart or in making it off-road capable, so what is the best (preferably cheapest) choice for a new controller?

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R&TBabich · 03-30-2021, 09:20 AM

Quote:

Originally Posted by GolfinDoc

Yikes! That was not what I was hoping to hear. So, my next question would be recommendations for a new controller. ...

What is the model no. of your OEM controller?

crash12888 · 03-30-2021, 11:07 AM

Before you replace the controller check the brushes in the motor.

03-22-2021, 04:57 PM	#1
GolfinDoc Not Yet Wild Join Date: Jul 2020 Location: Sumrall, MS Posts: 5	2002 ds IQ won't go but has solenoid click. 02 48V ds IQ ( fnr rocker switch) My kids were riding the cart a few weeks ago and it died shortly after leaving our house. They said the cart was acting strange and seemed to strain to get to the end of the driveway before it died completely. The cart has new batteries and a new charger so we knew it wasn't a charging issue. Upon inspection there was a wire loose at the motor (the terminal on the left if looking at it from the front of the motor). The motor terminal is severely corroded and the prior owner had used a hose clamp to force the wire on the terminal. I replaced the hose clamp with a proper ring-style connector and connected that to the terminal as best I could. (I will try to post a picture later). While the cart was up on jack stands I tested the new connection and when the pedal was pressed the wheels spun so I was satisfied that the fix worked. Unfortunately, now when you press the go pedal, the solenoid clicks and you can feel the cart begin to move, but it won't actually go anywhere. In both forward and reverse, there is a click from the solenoid and a "pull" to the rear, but the cart won't actually move. The cart rolls fine without the pedal pressed, so I know it is not an issue with over-tightened brakes restricting the wheel or any other kind of mechanical binding like that. This leads me to think that the issue is likely with the controller, but my mechanic skills are generally limited to things with gas tanks and I admit that I am a bit out of my element here. Where should I go from here? Sent from my SM-G973U using Tapatalk

03-22-2021, 08:59 PM	#2
WalterM6 Gone Wild Join Date: Apr 2017 Location: SE TN Posts: 2,227	Re: 2002 ds IQ won't go but has solenoid click. My guess is that there is still something wrong with the motor. Connect your ohmmeter between A1 & A2 you should read low ohms in the range of 1 to 2 ohms. Next measure between F1 & F2. You should get the same results. Then measure between each terminal and the case, you shouldn't have any reading. Theory is if the solenoid is closing that means the controller is telling the cart to run. And it has to be the motor, solenoid or cables. Another theory is you may have shorted the controller if you didn't disconnect the battery when you repaired the cable. Do you remember making any sparks?

03-27-2021, 07:00 PM	#4
WalterM6 Gone Wild Join Date: Apr 2017 Location: SE TN Posts: 2,227	Re: 2002 ds IQ won't go but has solenoid click. Yes.

03-29-2021, 07:04 PM	#5
GolfinDoc Not Yet Wild Join Date: Jul 2020 Location: Sumrall, MS Posts: 5	Re: 2002 ds IQ won't go but has solenoid click. Yikes! That was not what I was hoping to hear. So, my next question would be recommendations for a new controller. I have no interest in trying to speed up the cart or in making it off-road capable, so what is the best (preferably cheapest) choice for a new controller? Sent from my SM-G973U using Tapatalk

03-30-2021, 11:07 AM	#7
crash12888 Gone Crazy Join Date: Jan 2007 Location: Chesterfield, Va Posts: 6,021	Re: 2002 ds IQ won't go but has solenoid click. Before you replace the controller check the brushes in the motor.

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