This is a very easy to fix. All you need to do is reverse the positions of the wires between the motor and controller.
To do this unplug the motor from the controller. Then take a very small screwdriver and one at a time push the locking tab of the terminal pin flat with the pin and gently pull the pins out of the white plastic connector. Then restore the original positions of the terminal locking tabs using the same screwdriver and push the terminal pins back into the plastic connectors in the opposite positions that they were in when they were pulled out. I recommend marking the position of either the red or black wire with a permanent marker or tape so their original positions are not forgotten after the terminals are removed from the connector.
I have a crazy cart and it was working fine until recently. Now the Batt lights are illuminated and when I press the pedal there is a quick jolt and then nothing. I tried moving the wires but they are protected by a spring like sheath. Any suggestions?
If the motor wires are broken then the motor will usually turn on and off when the steering wheel is being turned. The newer Crazy Cart models with wire springs wrapped over the motor wires usually do not have this problem though.
Typically when there is consistently a quick jolt of power and then no power at all after the throttle pedal is pressed, the battery pack is dropping too many Volts under load which is causing the speed controller to turn off. The first thing I would do is test the Voltage of the battery pack with a multimeter before the pedal is pressed and keep watching the Voltage when the pedal is pressed and see if the Voltage drops. If the battery pack Voltage drops under 23 Volts when the pedal is pressed then the battery pack is the source of the problem and needs to be replaced.
Hi Mike, Razor added the spring around the motor wires on later model Crazy Carts to try to solve the broken wire problem. However it looks like the problem is still occurring. From what you described it sounds exactly like the broken motor wire problem that many people have experienced with their older model Crazy Carts.
The motor wire is built into the motor and is not replaceable as a separate part, however since it is just a simple electrical wire it can be repaired by splicing it back together, or by replacing a section of the wire by cutting and splicing new wires onto the old wires. If the wire is broken under the spring that presents a new repair obstacle though. The only way I can imagine removing the spring would be to cut the wires beyond the end of the spring and then pulling the spring off of the wires. Then the spring could be pushed back over the new wires before they are spliced onto the old wires to complete the repair.
Since the Crazy Cart's steering makes the motor wires frequently and severely bend that puts a lot of stress on the copper strands inside of the wires and they will sometimes fail from breaking in half due to metal fatigue. When replacing a section of the motor wires it would be best to use a wire that has a high copper strand count so it is very flexible. Most 14 gauge automotive primary wire has 19 strands of 27 gauge wire so they can not handle repeated bending very well. A better choice for a wire that will bend a lot is automotive speaker wire which typically has 41 strands of 30 gauge wire in a 14 gauge wire. Speaker wire is made with smaller copper strands than primary wire so it can easily bend around corners which makes it a good choice for applications requiring repeated bending. Not all speaker wire has such a high strand count though so if you do wind up purchasing speaker wire for the repair then I recommend making sure that it has a high strand count.
Please let us know if you have any questions.
Thanks guys! I appreciate it. I'm going to pick up some of the high strand count speaker wire and see if that fixes it. I'll update once I get it done, thank you again!