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Electric Club Car Electric DS, and Precedent golf cars



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Unread 08-28-2017, 03:37 PM   #11
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Default Re: Scottyb's solid state conversion V2

Mount the F&R switch over the big hole. I used a ruler and my eye. Place the ruler on the switch housing as shown. The switch should be about 1 inch below the seat.
With one hand hold the switch housing in the desired position and drill a 1/4" hole in through one of the side mount holes. Insert provided bolt and nut hand tight and again with the ruler in place, square this up with the cart body and drill the second hole. Tighten both fasteners.

NOTE - you are bolting plastic to plastic with a steel bolt. If you tighten this up like a gorilla you will cause the parts to fail. Snug and a bit is tight enough for the self locking nuts. This holds true for every nut and bolt in this kit. Over tightening electrical connections distorts the connectors and terminal threads significantly raising the probability of connection failures. Save your strength for the wheel nuts.

Plugs provided fill the left over F&R holes.
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Unread 08-28-2017, 03:46 PM   #12
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Default Re: Scottyb's solid state conversion V2

Wire up the F&R switch. I prefer 4 colors in my wiring so I can easily see what wire goes where LATER if something doesn't work. All small wiring should be 16g
When you get the switch wired up resist pluggin it into the housing. Wait until you test operation direction..... then you will know which way the switch should snap in
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Unread 08-28-2017, 03:57 PM   #13
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Default Re: Scottyb's solid state conversion V2

Alright - lets remove the old pedal.

I'm not going to go into the precautions needed to insure a safe job. This is a level 3 kit, all you level 3 mechanics know the importance of safety first. Carts are too low to the ground to work under with raising them. Be smart. Be safe.

Under the cart you will see this. From the instruction you see you are going to remove the linkage, this spring and this nut (each is numbered in the color instruction pics) and then from above remove the old pedal. Keep the small bolt and spring.
If the pedal won't slide off the shaft place a flat bar or large flat screwdriver against the pedal stock near floor level and tap with a hammer to drive the pedal off the shaft.

This is honestly better illustrated in the instruction. But it is still quite simple. Remember to keep the small bolt and spring.
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Unread 08-28-2017, 05:00 PM   #14
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Default Re: Scottyb's solid state conversion V2

Install the new pedal.
Notice the pedal has 4 made up wire connections. These wires are color coded as shown in the instruction. They easily reach their destinations. Do not pull on these wires to gain additional length.

Place the pedal template over the pedal hole in the floor so the L cut out lines up with the rear left corner of the old square pedal hole as seen from the drivers seat. Mark the 3 holes on the rubber mat with a pencil or silver felt tip market or such. Drill the holes through the mat and the floor pan.

Feed the pedal harness through the forward hole and place the bolts in the rear holes.
2 words of caution here.
1. Do not pull on the wire harness.
2. Do not pull on the wire harness.
Doing so can pull the wires out of the pedal and cause you to buy a new one.
So make sure the forward hole is big enough for the wire harness to pass through without pulling and tugging.
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Unread 08-28-2017, 05:09 PM   #15
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Default Re: Scottyb's solid state conversion V2

Use the same caution when tightening the pedal to the floor. It is aluminum and the bolts are self locking steel. Install the small thick L bracket 4 using the bolt from the pedal removal 3.
Adjust the rubber stopper 5 until the brake catches and releases with the brake pedal. I had to back the stopper adjustment off on my cart. Watch the brake pedal tooth and cog action in the last picture when setting this adjustment.
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Unread 08-28-2017, 05:42 PM   #16
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Default Re: Scottyb's solid state conversion V2

We're getting near the end. Land the 4 pedal wires as instructed and make up the few remaining wires like key switch power to solenoid and controller per plan. Controller to solenoid... hey that's it ! We are ready to install the big cable set. Follow the cable number system bing-bam-boom ! Put the batteries in per diagram and the rest of the cables.... install the charge socket.
What else? Nothing unless you want a kiddie switch or FN1.
The cart should look like this now - see the rocker switch is still not pushed into the housing.
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Unread 08-28-2017, 05:54 PM   #17
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Default Re: Scottyb's solid state conversion V2

Now take time to check your work. Check all the big cables by number 1-8. Check the battery pack voltage..... from your main + and -. Insure the main + goes to solenoid and the main - goes to controller B-.
Look over the small wires. Pay special attention to the diodes and small wires that connect with them. Double check any areas that you were not sure of when you installed them.

Double check and triple check.

If you want another set of eyes to look it over post pics in your own install thread (not here) and we will all look it over. We love install pics

When you are ready to test it, turn the key on, put the cart in gear, and lightly press the go pedal. Note which direction the wheels turn. Let off the gas and wait for the wheels to stop, switch direction and lightly press the gas, note which way the wheels turn and orientate the F&R toggle to match the F&R printed on the housing. Push the rocker switch into the housing. Tidy up you wiring. Take special cart that no wires or pedal harness is hanging down below the cart where something could snag it.

Go for a short test ride, comeback and remove the seat for another check.

Looks good, nothing got hot? Congratulations - you did it.
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Unread 08-28-2017, 06:00 PM   #18
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Default Re: Scottyb's solid state conversion V2

Okay - Got problems? Got nothing? Don't panic. It's often something simple. Start a new thread and post your install troubles in your own thread, not here please.
I will be happy to help

The kit comes in 3 models for Ezgo and Club Car and a Universal kit for 'other' carts. Post questions about the kit here.
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