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Unread 06-02-2015, 04:49 PM   #1
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Default Regen braking question. My cart has 2004 components??

My $200 Craigslist 1996 Club-Car DS project

Here is a link to my project/build that I started. I have a couple of questions that I can not find in the searches. The first is a general question about newer parts on an older cart. While going through and cleaning my cart and getting it running again I am noticing that a lot of the components on the cart are dated 2004. Could this be a Club Car factory refreshed cart? The controller, wiring harnesses, old Trojan batteries and tires have 2004 dates on them. The charger is from 2003. Could of maybe been a refresh in 2004 before it was sold?
Also can someone tell me how the regen brakes are supposed to work? When I first got it running again I felt it working in reverse and only once in forward then it seemed to stop working and freewheels down hills. A common problem or something I can check or clean? If I go quick in reverse and let off the pedal I feel the cart slowing down like a jake brake effect. But it only did this once in forward after the new batteries were put in. Any help or info appreciated.
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Unread 06-02-2015, 07:15 PM   #2
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Default Re: Regen braking question. My cart has 2004 components??

In looking at your photos you appear to have a 1996 Regen 1 cart (rocker switch for fwd/rev). I'm not sure CC rebuilt any of those - but Regen 1 controllers did fail frequently, and its likely you have a replacement Regen 1 (probably GE grey colored) controller. Not too uncommon to have a replacement charger also.

If it hasn't been altered too much, and its Regen 1, then you will have no run/tow switch. You will have two solenoids (one of which connects to a coil) and a RED battery light (not amber, although those were frequently changed also).

Your motor will have a grey colored pigtail/plug coming out the back. If it is unplugged or cut, the dynamic braking will not work (dynamic means a relatively gentle deceleration from top speed) but your hill brake (like an extreme jake brake) will still work when you stop on a hill - then release the brake.

Post a photo of your controller (on frame behind passenger) - the pigtail plug on the motor; and the solenoids/coil to confirm for sure. But I'm almost positive its Regen 1. Which explains why it might have been on sale for $200 - they're a bit "tricky" (the P.C. word) to troubleshoot and maintain.
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Unread 06-02-2015, 07:22 PM   #3
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Default Re: Regen braking question. My cart has 2004 components??

Here is a wiring diagram for Regen-1 - see if your wire colors appear to match - you most likely have an adapter plug in-line going to the newer controller also. See photo of the cable adapter on a replacement Regen 1 controller.
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Unread 06-03-2015, 12:21 AM   #4
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Default Re: Regen braking question. My cart has 2004 components??

Joesam its a regen2 controller. Probably was converted from a regen1 to regen2 in 2004
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Unread 06-03-2015, 09:35 AM   #5
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Default Re: Regen braking question. My cart has 2004 components??

Thanks for the replies. I am learning as I go, new to the golf cart world LOL. What is the difference between regen 1 & 2? Just upgraded electronics? Everything else seems to work great on this cart so far. I haven't tried any hills yet or long distance drives. I'm planning on heading to the camp later today so I will check out the wiring and take more photos. Maybe something was disconnected to disable the regen braking. I haven't looked at the motor wiring yet but everything on my quick inspection seemed to be hooked up and unmolested. Didn't see anything cuts, splices etc. I plan to go with a mild lift, maybe 3" and 20" tires on 10" wheels but may also go 6" with the 22" tires. Probably will not upgrade motor and controller if it's running OK. It's just a campsite cart but it does get muddy and the roads are all crushed stones. Anything to soften the ride a little.

Last edited by tmd07; 06-03-2015 at 09:36 AM.. Reason: My typo errors!
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Unread 06-03-2015, 10:01 AM   #6
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Default Re: Regen braking question. My cart has 2004 components??

I'm learning too - I had heard of Regen 1 to 2 conversions, but have no idea of the details and have never seen one.

David....just for curiosity - since it was converted, maybe you'd know - or had seen one (although these aren't really in your wheelhouse - I realize)

1) Do you think they changed the harness & added run/tow switch? (I would think they would need to - since a Regen 2 controller wouldn't have the solenoid "timeout" function used on Regen 1).

2) Do you think they swapped the pot-box for a V-glide or kept it....or since it may have been 2004, maybe MCOR?

I realize you haven't seen this cart - but wondered if you had ever run across one of these conversions.
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Unread 06-03-2015, 01:36 PM   #7
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Default Re: Regen braking question. My cart has 2004 components??

The conversion kit did not include a tow/run switch. The internals were a little bit different for the Conversion Regen 2 controller than the regular service replacement Regen 2 controller. It was designed to work as the Regen 1 controller did. It would essentially be in tow with the key off and in run with the key on. I'm sure it had a V-Glide to begin with. I've never seen a Regen car of any sort with a potbox. Those were always on series cars based on my experience. If it was converted in 2004 it's possible that they may have used an MCOR conversion kit.
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Unread 06-03-2015, 01:59 PM   #8
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Default Re: Regen braking question. My cart has 2004 components??

Well - let me be the first! My '96 Regen 1 has a (still working perfectly) pot box. I always thought all '96 Regen's had them, and that the early '97's jumped back to V-glide because the pot box had some unpredictable "features" - but to be fair, mine is the only Regen 1 I've ever worked-on, so honestly, my clue meter is pinned at zero (as to whether that's true).
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Unread 06-03-2015, 04:59 PM   #9
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Default Re: Regen braking question. My cart has 2004 components??

Yeah it's definitely the first I've ever seen or heard of. You've got quite the collectors item there.. lol
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Unread 06-03-2015, 05:09 PM   #10
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Default Re: Regen braking question. My cart has 2004 components??

The only 96 Regen 1 with a potbox (known to David) that actually works flawlessly in stock form
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