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Upon initial power up, this cart lunges forward and stops. Reset of tow switch would re-engage(click) motor and cart would start and lunge again. After about four times, cart would run fine. Bypassed tow switch and after thinking problem solved, next morning cart still acted the same. After multiple starts and stops, it engages and runs fine. Cart is in great shape, no loose wires, new batteries that charge up fine. Where might I start to look? or do I need to take it to the cart shop?
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Before considering pursuing more complex repairs inspect the motor brushes and conduct a load test on the batteries even though they seem new. This can help identify and address potential simple issues that may be contributing to the cart's erratic behavior. Let's start by checking the motor brushes and performing a load test on the batteries. More info on that below.
The motor brushes conduct electricity to the armature facilitating motor operation. Over time these brushes can wear down due to friction and use leading to intermittent electrical contact and issues like the cart lunging forward and stopping. If the brushes are worn or damaged, they may fail to maintain consistent contact with the armature resulting in erratic motor behavior. Regarding the batteries, lets assess their state of charge. A load test can help determine the batteries' capacity to deliver power under load conditions. A 48V lead acid battery pack should read around 50-52 volts when fully charged. To determine their capacity to deliver power under load conditions, a load test is needed. You can perform this test using a multimeter connected to the battery pack while driving the cart up a hill. During the load test, observe the voltage readings on the multimeter. Under load, a healthy battery pack should not drop significantly below 48 volts. If the voltage falls sharply, it indicates that one or more batteries in the pack may be weak or failing.
In Yamaha carts a weak or bad battery can mimic symptoms similar to those described. If the pack voltage drops significantly under hard acceleration, the controller may detect a fault condition and shut down motor operation until the run/tow switch is reset. This protective measure prevents damage to the electrical system and components. If the motor brushes and batteries test fine, we can move on to solenoid and controller diagnostics. Let me know how it goes and if you need any further assistance feel free to respond!
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