Please let me know if you have any questions.
Is there an easy way to test the power switch?
So a little more diagnosing...I have power to the switch at 26v. I checked the charging port and have no voltage; however, the wall charger reports operational based on the instructions here:http://www.electricscooterparts.com/troubleshootingspeedcontrollerdoesnotwork.html The batteries are putting out almost 26v. I have checked the connections and the only thing I am not getting power on is the blue and yellow leads from the control module to the motor. This "should" be 24v from what I understand. Any other advice or recommendations?
After dismantling almost the entire cart and checking each thing meticulously, I narrowed the issue down to the on/off switch. I ran to Radio Shack to get a new one; however, they did not have anything remotely similar. I returned home and began diagnosing the switch. I took it apart to see if it was fuzed inside. Unfortunately it was not. However, upon taking it apart, I found a small piece of paper-like cardboard between the contacts of the switch. I put it back together (backwards the first time) and it worked like a pro. So, before buying a new switch or anything, I recommend taking everything apart to check it out. This was very odd, but now have a happy carter! Thank for your assistance in diagnosis.
Power switches are a popular part in our store so it does not surprise me that the switch was causing the problem. It is interesting to hear that the issue inside of the switch was a piece of insulation paper that had come loose and wedged itself between the switch contacts. I have always just replaced switches and never thought to take one apart to see what was wrong inside of it. Gary, you will definitely get this forum's MacGyver award of the month for that!
Looks like you were right, the lines going to the motor were slightly severed at the pinch point below the steering wheel. Not enough to break the plastic, but enough to sever the thin copper wires inside. They should have put in a rubber grommet or something, the metal spring protecting the wires is basically useless. My dumb butt thought it was actually at the motor at first, so I took apart the motor. Bad idea. Now I can't get the motor back together and it ESP says the motor is on backorder. Any idea when new motors will be available?
I have a similar problem in that I thought the problem was in the accelerator pedal. I took it apart and found an odd looking magnetic strip of metal that had come out. I put it back in (apparently upside down) because it started working again but accelerated when I the pedal was let out. So I flipped it, and installed it again and now it accelerates when you push on the pedal. BUT. After I put it back together, it keeps falling out and then the thing won't work again. Do I need a new Pedal? Or do I need crazy glue?