98 DS- Please help with a few wiring questions about my new project

Mparsons

Hi guys I'm new to the golf cart sceen, and I've seemed to have found myself with a new project.....a 98 club car DS. Once again I'm no expert but I believe the model I have is equipped with a regen gen 2 motor and controller. Anyways the previous owners had the batteries stolen and a few of the wires around the batteries were damaged. I've looked at your wiring diagrams and I'm happy with everything I see except two things.

1. There is a grey wire with an inline fuse holder that comes off the charging port. I don't have a fuse there and I'm wondering what size it should be?

2. Just behind the center batteries tray there is a resistor (large coiled wire) with two wire connections that have been cut. I can't find this resistor on any print I've seen. I've got the much larger resistor that is attached to the top of the coil and accessed via the motor/ computer hatch so don't confuse it with that one. This unknown coil is accessed under the seat. Can anyone direct me to an electrical print or take pictures of where those wires on your cart terminate?

Thanks so much for any and all help!

BGW

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Aflyer

Welcome Mparsons,

I can help you with the first one that is easy, it is a 3/8 amp fuse. I know because I have a blown one.

Sorry I do not have the answer to question 2.

Aflyer

Golfdog

If you have the large coil resistor then you have a Regen 1 system not Regen 2 which did away with this coil.

Mparsons

Unfortunately I've only been a member for 2 days so the forum system won't allow me to upload an image of this unknown resistor!

Anyways Golfdog, I've got the silver controller which is gen 2 right? Best I could find, the gen 1 units used a black T shaped controller?

Mparsons

Golfdog and Aflyer, I was able to upload images under my profile as an album! Feel free to copy and paste the unknown resistor image here if you want, I'd really appreciate it

Sergio

The Regen II until S/N 0106 had the external DB Solenoid with the Resistor coil On Top of the Solenoid.

I just saw your pictures and there has been modifications done.

Your best bet if you keeping the old Regen system is to totally eliminate the DB solenoid and unplug the speed sensor.

Mparsons

Sergio is there any write up about bypassing the regen system? I'm sure if I bypassed it is wouldn't need to worry about my unidentified coil.

Sergio

It is pretty simple, use the wiring diagram below for reference:

http://www.buggiesgonewild.com/attac...s_-regen2-.jpg

Disconnect the Orange/White and the Brown wires from the DB Solenoid.

Put some electrical tape on the ends so they will not short against anything.

Run a cable from Motor A2 directly to Controller terminal A2.

Unplug the Speed Sensor so the Controller will not try to activate Dynamic Brake.

Mparsons

Just wanted to thank all of you guys for your help. I ended up buying 8v Duracell batteries for the cart. It did move when I installed them, but it would barely move in reverse and somewhat slow in forward. I then bypassed the regen system and the cart instantly ran great! Just wanted to say thank you for all the advice!

Aflyer

Mparsons,
Glad you were able to get it all worked out.

Sergio has the answers once again!! Great job Sergio.

Aflyer