"Click" Only Go Forward at 60%

[weekster]

I recently finished a rebuild of a 48V 2002 Club Car DS. The Plum Quick motor, Alltrax AXE controller, HD solenoid, and 2 gauge wires were bought from Carts Unlimited in 2012 and were previously on my 2000 Club Car DS that my son wrecked. I replaced the the batteries with a lithium pack from Extreme Team Carts. I also bypassed the OBC.

Upon completion, the cart would sometimes "Click" No Go, and sometimes it would Go in both Fwd and Rev. I connected my computer to the Alltrax AXE Controller and saw that the throttle was displaying different outputs at different times with the accelerator pressed all the way. I thought it may be the MCOR so I replaced it with a MCOR4 conversion from Revolution Golf Cars.

Now it won't go in reverse at all and the max throttle is @ 60% in Forward. It also seems to have a longer delay between pressing the throttle and the motor engaging than it did before.

Battery is fully charged and showing 53 Volts. I have checked and rechecked all of the connections and they are tight.

Any ideas? Bad solenoid perhaps?

[aalbert77]

How many inches is pedal down before MCOR clicks? Mine switched at 3" or 50% down, so I removed the slack in throttle linkage by sliding a nylon bushing over the horizontal linkage shaft and it improved switching to 1" down.

I used .0325 ID x 29/64 or 15/32 OD x 0.4-0.5" long
Home Depot Internet #204276564 Model # 815028 Store SKU #595609

[Goober11]

Originally Posted by aalbert77

How many inches is pedal down before MCOR clicks? Mine switched at 3" or 50% down, so I removed the slack in throttle linkage by sliding a nylon bushing over the horizontal linkage shaft and it improved switching to 1" down.

I used .0325 ID x 29/64 or 15/32 OD x 0.4-0.5" long
Home Depot Internet #204276564 Model # 815028 Store SKU #595609

Like that idea.

[weekster]

Originally Posted by aalbert77

How many inches is pedal down before MCOR clicks? Mine switched at 3" or 50% down, so I removed the slack in throttle linkage by sliding a nylon bushing over the horizontal linkage shaft and it improved switching to 1" down.

I used .0325 ID x 29/64 or 15/32 OD x 0.4-0.5" long
Home Depot Internet #204276564 Model # 815028 Store SKU #595609

I did seem to have some throttle linkage issues but the MCOR is now clicking @ 1" down, still have the same problems.