2002 gem cart ride for fun motor

21

I would look at P1-Black and P4-Green on your cable. Note that you have two green wires in your example. Sometimes there is a shield on that cable. It’s all part of the sometimes screwy wiring plan you can run into on these Gem cars. It helps if you check multiple sources.

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You can also check at the controller.
Is this a T1 or T2 controller?

Have you tried booting up the controller yet?
For now - Disconnect that Main Contactor so it is not operating. It should NOT be clapping every time the key is turned.

(Bare minimum)
KeyOFF.
Main Neg cable on top of the controller connected.
On the 23p Main Harness connector (on top of the controller) Find the White and Gray wires (Pin1 and Pin2)
Take those to B+ over on the pass side of the dash.

If all is well, the PID should light up.
Observe if Main Pos cable (on top of controller) now has B+ on it.

22

I would look at P1-Black and P4-Green on your cable. I have 5V across the p1 and p4 key off. checking at the connector off at the BDI

23

is this correct voltage for said pins?

Yes, That is what you should see on those pins. How did you probe for this?

  • Remove the 23p and stick probes in the end of the plug?
  • Back probe the wires from the wire end? (with the 23p still in place)
  • Pin through the wires?

With the Main Harness plug in the top of the controller, You should also see B+ across the big cables on top of the controller (with the main relay/contactor disconnected)

24

Yes< I Back probe the wires from the wire end? (with the 23p still in place)

Yes< I always have 72V at the top of the controller with battery switch on. Not sure where you what me by disconnect at the main relay/contactor…tho

25

I always have 72V at the top of the controller with battery switch on. Not sure where you what me by disconnect at the main relay/contactor…tho

You have two little wires going to that contactor.
Disconnect the black wire.

KeyON
Check for B+ across the Pos and Neg posts across the top of the motor controller.

26

Hello, e-mail sent I do have 72V across the pos and neg on the controller with the small black wire disconnected from the contactor, I also have the same results with the same results with the key off. Hmm

27

Hello, do you have any thoughts on my results that you had me check? Thank you for your help..MB

28

I’ve been traveling and just got back yesterday. Still catching up.

In summary-

  1. The small black feed wire is off the Main relay?(the orange thing)
    Verify also that is is no longer active when you turn the key?

  2. You still have B+ across Pos and Neg on top of controller?
    – Key ON and Key OFF ?
    – Then check for B+ across Pos and Neg on top of controller when Main Batt Sw to OFF.
    (You may note the V dropping after you switch Batt Off)

  3. What was results of power going up to BDI?

29

Hello, thanks for your reply.

at P1-Black and P4-Green on your cable. I have 5V across the p1 and p4 key off. checking at the connector off at the BDI

30

Also for question 1 the orange thing no longer active

question 2 B+across pos and neg on top off the controller key on and key off.

and no Volts across the controller with main batt switch off

31

I was hoping to see more of an indication of life out of all this testing but it sure looks like the PID(Dash display) is dead, but also it could be the controller. It is tough to tell without plugging into it to see if the logic board is booting up.

I’d send both of those into FSIP to have checked out and/or replaced.