2002 Club Car DS - Cutting In and Out

M

maddogkarts

New Member
Hello,
I have a 2002 Club Car DS that is cutting in and out. With the cart on, there are moments where the cart will move and solenoid will click. Then there are times that you have to shake it back and forth and continue to push pedal down to get it to go. Does this just sound like a simple bad solenoid? Someone said something about the MCOR, or maybe the OBC. Just trying to get better with figuring out electrical issues with all carts.

What is the best way to completely test a solenoid as well? Thank you!
 
maddogkarts said:
Hello,
I have a 2002 Club Car DS that is cutting in and out. With the cart on, there are moments where the cart will move and solenoid will click. Then there are times that you have to shake it back and forth and continue to push pedal down to get it to go. Does this just sound like a simple bad solenoid? Someone said something about the MCOR, or maybe the OBC. Just trying to get better with figuring out electrical issues with all carts.

What is the best way to completely test a solenoid as well? Thank you!
Click to expand...
what it sounds like is a loose connection
get a print and a voltmeter
start tracing out the run circuit
 
The solenoid clicking sounds like your big clue. The sol coil gets power from the key switch, MCOR foot switch. The MCOR is an inexpensive suspect.
 
There are a lot of inputs to the controller. Get a diagram in the resource section and start checking all the inputs to controller. The mcor has 2, the foot switch inside sends voltage to controller when pedal pushed down. The TPS inside sends a 5000 ohms to 0 ohms input depending on pedal up or pedal down telling controller how far the pedal is pushed down.. The F&R switch (or lever) sends a direction input. Solenoid is activated by controller to allow high current to motor. Key is to turn on cart. First thing is battery cables, make sure they are clean and tight and you have 51 volts fully charged.
 
The MCOR is the most likely intermittent input. REF. the "2002 IQ System Electric Vehicle Maintenance and Service Supplement" to trouble shoot the problem. Depending upon your electrical skill & patience, an option is to replace to MCOR $40, TOW/RUN Switch $13, F&R Switch $13, Relay/250 ohm (pay attention to the diode) $ 29 & Key Switch in that order. For about $100.00 you could invest some time cleaning all these connections as you replace these low cost parts that have been in service for 22 years.

Jeff gave good advice, I add, down load the service manual, the supplement, take pictures of every connection prior to removing any part!

Good Luck!
 
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