Bad Boy Buggy Sparks when the Negative Cable is Connected to the Battery

[bucketbryan]

I have a 08 Bad Boy Buggy 4×4 48v, bought it around 5mos ago, was told that the controller was bad ,it was,so I purchased one through a local dealer (redbrush outdoors). He gave me a wiring diagram for my cart, so I got it moving but not in auto, but in 4×4 mode it would run great I thought. I only right at 4 miles to a charge, then I switched batteries around and now when I go to hook up the negative cable to the battery a big loud spark happens

 

[Pat911]

How did you switch batteries around? Did you swap in new batteries or just move your existing ones around?

Can you post a picture of your batteries and their connections?

 

[bucketbryan]

Switched between two carts

 

[bucketbryan]

Would either of the solenoids cause any of this

 

[bucketbryan]

I have replaced the key switch, the foot control parts ,taillights ( they were broken) ,and another key switch, the first one burned out, this is why I found this problem

 

[bucketbryan]

Here is my new controller

 

[Pat911]

So to clarify, you changed the controller over and the cart worked except that it would not run for long.

You swapped in 4 x 12v batteries from another cart and you now get a spark when you make the final connection. Did you get a spark with the old batteries when you first replaced the controller and reapplied power?

Theres a few disconnected wires toward the bottom of the picture, are those the ones you’re trying to reconnect and to where?

 

[bucketbryan]

The wires that are not connected are to the charging port, winch, and new light kit.

 

[Pat911]

Are you able to power down the controller before connect the battery leads? Like the other thread, it could be just the capacitors trying to charge up.

 

[bucketbryan]

I have it disconnected and still sparked ,it even sparked going ground to ground

 

[Pat911]

What do you mean ground to ground? Take a photo and either mark on it, or explain what you’re connecting to what when it sparks.

 

[bucketbryan]

Ok in morning I can send a video if that works

 

[bucketbryan]

I got it running, but it still won't run in auto ,but it will run great in 4×4 .
Can't figure out why.
It gets around 5 miles on a charge

 

[Pat911]

What did you do to get it running?

 

[bucketbryan]

I found two wires that were hooked up wrong

 

[bucketbryan]

What would cause it to start off really fast then slows down about half ,continuing to run

 

[Pat911]

Bad batteries, sagging after a certain time? controller settings?

For the batteries, you can check voltage under load and see what you get.

 

[bucketbryan]

How do I check the controller settings?

 

[Pat911]

That’s not my area, maybe someone else can chime in here.

 

[Diode]

If it's the stock controllers you don't.