|11-07-2015, 08:13 PM||#1|
Not Yet Wild
Join Date: Nov 2015
1995 DS to MCOR4 Conversion - AM293201
I would like to try to give a little back to this forum as a way to repay for all of the information
that I have gained here over the years. So I thought I would post this information about how
my brother and I installed a Pre-MCOR to MCOR4 Kit (AM293201) on our 1995 Club Car DS.
Hopefully to help with anyone’s questions, here is some background information about the cart my
brother and I bought several years ago for our hunt camp. Our cart is used almost exclusively in the
woods and the serial number on our cart indicates that it is a 1995 Club Car DS (48 volt), also when
purchased the cart appeared to be completely stock. The first upgrades that we made were to install a
lift kit, large off road tires, GE D395 motor, HD F/R switch, high amperage solenoid, larger cables
and an Alltrex AXE controller. We soon realized that the batteries needed replacing, so new batteries
After a year or so of use, we were not happy with the throttle response of the stock Club Car stepped
potentiometer. The cart would jump from one speed to the next and would not creep very well. So we
first tried changing the values of the resistors in the stepped potentiometer. This helped and could
have probably been made to work given time to determine the exact resistor values that we would
need to give an acceptable throttle response. However, we really wanted a smoother and constantly
variable throttle response. So we bought a PB-6 throttle potentiometer (0-5k). At first, it
worked very well and we thought we had solved our throttle issue. However, the PB-6 is not sealed
very well and after a year or so, oxidization the PB-6’s internal potentiometer would cause the cart to
jerk and jump. This was very dangerous, especially in the woods or on rough terrain. Placing the cart
in neutral and pumping the gas pedal would “clean” the potentiometer and the cart would operate
great for a short period of time. However, this got old really quickly and, after a few close calls, it
was obvious that a new solution was in order.
Meanwhile, someone else at the camp had purchase a 1996 Club Car, which had a newer pedal
design that included a MCOR. He asked us to upgrade his cart with the same off-road items we had
on our cart. After the power and lift upgrades, his cart ran great and his MCOR continued to operate
smoothly. So, we ordered the Club Car #AM293201 - MCOR 4 Conversion Kit to replace the PB-6
throttle potentiometer on our cart.
I hope this is of some help to someone.... Sorry this is so long and the files are so big... First real post to the forum...
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|11-09-2015, 04:58 PM||#2|
Not Yet Wild
Join Date: Nov 2015
Re: 1995 DS to MCOR4 Conversion - AM293201
When the ZIP files that are attached to the above post are extracted, you will have the detailed PDF conversion document for installing the AM293201 MCOR4 conversion on a 1995 style pedal group as seen below.
The PDF document was way too large to upload as a PDF, so I had to divide it up and compress it to meet the file upload requirements of the forum...
Thanks for looking...
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