2001 Club Car Series 48v - starting from a dead stop the cart starts out fine until about 5-7mph and at midway pedal position it dies out. If you push to the floor it will jump/jerk a few times pretty heavily and kick right into full sprint.
History of things already done and checked for:
1. Batteries are 6 Trojan - 8volts .. Readings on each battery are all at 8.5v
51.2 across the entire pack - even load tested - batteries are good. Ruled out batteries dropping under load.
2. Replaced MCOR with new one
3. Since NEW MCOR did not fix the jerking - I thought possibly I got a new defective one. Did the paper clip bypass - Still surging and jumping
3. New Forward / Reverse Switch - one that was initially on the cart had seen better days, all the copper contacts on the back of the switch had burn marks in them and one side had melted. The cause was some friends repeatedly slammed it in forward / reverse repeatedly without letting off accelerator and caused the switch some serious injury.
I believed the switch was the main cause of the jumping because it was hard to get into forward or reverse, which made me think the poor contact was causing the issue. Replaced with new forward / reverse - much easier to get into forw/rev now, but still jumping forward at mid throttle!
4. Put brand new cables 2 gauge wires on the batteries. Includes 2 longer cables for batt #1 and batt #6 to run to solenoid and controller.
One thing I noticed was cable was too thick to fit through the fused hole. So I put a new 4 gauge off neg battery to controller so it would fit and wouldn't cause charging and lockout problems.
I removed the stock left yellow cable off the solenoid that runs to the controller and put the new 2 gauge wire in place of it. Right side of solenoid large post is red 2 gauge cable running to battery.
5. Checked all inline fuses, checked for any corroded wires or bad wire lugs.
LASTLY
The only other thing I can think of - even though the solenoid is clicking and seems to be working properly, possibly it's the output side causing the issue
OR
The controller is dying on me.. I'm leaning towards try new solenoid
Any ideas guys?! I'm ready to feel smooth acceleration, this has been a project to say the least
History of things already done and checked for:
1. Batteries are 6 Trojan - 8volts .. Readings on each battery are all at 8.5v
51.2 across the entire pack - even load tested - batteries are good. Ruled out batteries dropping under load.
2. Replaced MCOR with new one
3. Since NEW MCOR did not fix the jerking - I thought possibly I got a new defective one. Did the paper clip bypass - Still surging and jumping
3. New Forward / Reverse Switch - one that was initially on the cart had seen better days, all the copper contacts on the back of the switch had burn marks in them and one side had melted. The cause was some friends repeatedly slammed it in forward / reverse repeatedly without letting off accelerator and caused the switch some serious injury.
I believed the switch was the main cause of the jumping because it was hard to get into forward or reverse, which made me think the poor contact was causing the issue. Replaced with new forward / reverse - much easier to get into forw/rev now, but still jumping forward at mid throttle!
4. Put brand new cables 2 gauge wires on the batteries. Includes 2 longer cables for batt #1 and batt #6 to run to solenoid and controller.
One thing I noticed was cable was too thick to fit through the fused hole. So I put a new 4 gauge off neg battery to controller so it would fit and wouldn't cause charging and lockout problems.
I removed the stock left yellow cable off the solenoid that runs to the controller and put the new 2 gauge wire in place of it. Right side of solenoid large post is red 2 gauge cable running to battery.
5. Checked all inline fuses, checked for any corroded wires or bad wire lugs.
LASTLY
The only other thing I can think of - even though the solenoid is clicking and seems to be working properly, possibly it's the output side causing the issue
OR
The controller is dying on me.. I'm leaning towards try new solenoid
Any ideas guys?! I'm ready to feel smooth acceleration, this has been a project to say the least