Yamaha electric operating problem

[bryon4]

hey guys:
I have a 1997 Yamaha electric cart. Just replaced the solonoid and replaced all 6 batteries. Upon depression of the accelerator pedal, the cart does nothing maybe 60 % of the time. The other 40%, it will operate as expected. Any idea what is causing this? Thanks

[golfcartg]

It sounds like a loose or broken connection on the high current cables either connecting the batteries or to the motor. When there's a loose or broken connection the electrical circuit can become intermittent. This causes inconsistent operation as the cart's motor may receive the necessary power only part of the time. When you press the accelerator pedal and nothing happens, it's likely because the circuit isn't complete due to a faulty connection. Conversely, when the cart operates correctly, the connection is temporarily stable. This inconsistency can be frustrating and potentially damaging to your cart's electrical system if not addressed promptly.

Start by inspecting all high current cables and connections. Begin with a visual inspection, looking for any obvious signs of wear, corrosion, or damage on the cables and their connectors. Check for tightness at every connection point; loose connections can cause arcing, which leads to further damage and intermittent operation. If you spot any corrosion, clean the terminals and connectors thoroughly using a wire brush or terminal cleaner to remove any buildup. This creates a clean conductive surface for electricity to flow. After cleaning reassemble everything making sure all connections are tight and free of any debris.

To be thorough, you could use a multimeter to test for continuity in the cables. This helps identify any breaks or high resistance areas that aren't visible to the naked eye. Inspect each battery terminal, the connections between the batteries, and the cables leading to the motor and controller. Pay special attention to the points where cables connect to the motor and controller as these are critical junctures for the flow of electricity.

I'm attaching the service manual which includes the wiring diagram so you can double check your wiring. Other potential causes for your issue could include a faulty accelerator pedal switch or worn motor brushes. The accelerator pedal switch signals the motor to engage, it could be worn out or malfunctioning leading to the intermittent operation. Let me know if you have any questions!