Poopsie's on Bypass

fsu1tm · 11-10-2017, 06:32 AM

OK. No ragging. I bought this 1990 CC DS about 5 years ago and my wife named her Poopsie. I guess it's an appropriate name since she probably never did more than 10 MPH. But now, Christmas has come early. I ordered from ScottyB the deluxe 500 setup with the F/R toggle switch, HD Solenoid, voltage reducer, electronic pedal, and "child, mild, wild" switch. Oh, and I got a new charger.

As you'll see from the pics, I've ripped her heart out which, if any of you have a loved one whose gone through heart surgery, means they are on "bypass". I purchased a piece of angle at HD for installing the Alltrax but wouldn't you know, I cut too short and had to go back for another. I had it installed straighter with the shorter bar but what the heck, no one will ever see with the seat closed. Now I just need to get some new drill bits (aluminum is tougher than it looks) to mount the solenoid. Hopefully I'll be finished this weekend if honey do's don't get in the way. I'm sure I'll have a lot of questions so all you experts stay on standby

NoleFan4Ever · 11-10-2017, 08:07 AM

Unbolt that piece of angle and redrill it. You have too much money (and will be time) to leave it like that...

Plus, Poopsie may not run correctly if the internal leveling switch is off on the controller due to it and you hit sharp turns or steep hills....

But seriously, enjoy the time, go slow, recheck and retighten every connection at least twice, and do not put power to anything until the fuses are in and everything is complete and actually ready to ride....

Good Luck!

Sergio · 11-10-2017, 09:08 AM

You need to turn that angle piece upside down (L pointing down) so it has a flat profile to mount the controller.

You can either mount it under the frame or notch a piece on each end if you are mounting over the frame like you have.

The way it is now it increases the possibility of a short and it will create too much stress on the electrically good but somewhat "mechanically flimsy" Altrax high current tabs.

fsu1tm · 11-10-2017, 09:44 AM

Both good suggestions. I knew it'd be a good thing to post pics of the conversion as I went along.

tag50 · 11-10-2017, 02:20 PM

Note on drilling aluminum. Most bits are beveled for steel not aluminum so the bit gets too hot. Drilling aluminum needs a lot of pressure and very, very slow RPM's. You'll know when you have it right by the long curls coming off the tip.

.

jsmith294 · 11-11-2017, 09:56 AM

Are you planning to replace the motor?

jsmith294 · 11-11-2017, 10:02 AM

Sorry about the multitude of questions, but I am considering a similar upgrade for my 2003 series drive DS. The new controller looks like it will be exposed to road debris and puddle splash in its intended location. Are you going to use a shield? Is the controller water resistant? Thanks!

scottyb · 11-11-2017, 10:07 AM

Quote:

Originally Posted by jsmith294

Sorry about the multitude of questions, but I am considering a similar upgrade for my 2003 series drive DS. The new controller looks like it will be exposed to road debris and puddle splash in its intended location. Are you going to use a shield? Is the controller water resistant? Thanks!

That same controller was on a member's cart that went through the ice last winter. It took the owner 24 hours to retrieve the cart from the water. The cart ran as soon as it was dried out.

This controller is advertised as water resistant and splash proof. I would not suggest exposing it to a pressure washer.

fsu1tm · 11-11-2017, 03:56 PM

I'm not changing out the motor right now. Saving that for a later project. Hoping that the upgrade will show the motor is OK.

fsu1tm · 11-11-2017, 04:15 PM

Progress is going OK but I can tell that I will have a few questions. I'll save those for the next post. Right now is time for an update.

F/R micro switch mounted along with HD F/R switch. Lot's of questions here (next post).

Solenoid mounted. I chose the bottom to be +. I didn't have any black wire so I ran green to J1 black on the Alltrax. I also ran red to J1 red on the Alltrax. You can see the resistor and diode installed in the pic.

I ran new wires from the key switch to Battery + and to the red/yellow on the foot pedal. To connect to the red/yellow, I striped both wires back, slid a piece of heatshrink over one wire, and then soldered together. I then coated with dielectric grease, slid the heatshrink over the connection, and applied heat.

Gotta ask, Nole and Sergio. Does the controller mounting look better? Mounting the angle aluminum from the bottom sure was easier.

11-10-2017, 08:07 AM	#2
NoleFan4Ever MOD of all BS! Join Date: Sep 2011 Location: Florida Posts: 17,477	Re: Poopsie's on Bypass Unbolt that piece of angle and redrill it. You have too much money (and will be time) to leave it like that... Plus, Poopsie may not run correctly if the internal leveling switch is off on the controller due to it and you hit sharp turns or steep hills.... But seriously, enjoy the time, go slow, recheck and retighten every connection at least twice, and do not put power to anything until the fuses are in and everything is complete and actually ready to ride.... Good Luck!

11-10-2017, 09:08 AM	#3
Sergio Gone Wild Join Date: Sep 2012 Location: Charlotte, NC Posts: 9,329	Re: Poopsie's on Bypass You need to turn that angle piece upside down (L pointing down) so it has a flat profile to mount the controller. You can either mount it under the frame or notch a piece on each end if you are mounting over the frame like you have. The way it is now it increases the possibility of a short and it will create too much stress on the electrically good but somewhat "mechanically flimsy" Altrax high current tabs.

11-10-2017, 09:44 AM	#4
fsu1tm Gone Wild Join Date: Jan 2015 Location: Seminole Country Posts: 836	Re: Poopsie's on Bypass Both good suggestions. I knew it'd be a good thing to post pics of the conversion as I went along.

11-10-2017, 02:20 PM	#5
tag50 Gone Wild Join Date: Apr 2014 Location: Oregon City, Or Posts: 1,977	Re: Poopsie's on Bypass Note on drilling aluminum. Most bits are beveled for steel not aluminum so the bit gets too hot. Drilling aluminum needs a lot of pressure and very, very slow RPM's. You'll know when you have it right by the long curls coming off the tip. .

11-11-2017, 09:56 AM	#6
jsmith294 Gone Wild Join Date: Feb 2014 Posts: 156	Re: Poopsie's on Bypass Are you planning to replace the motor?
jsmith294 Gone Wild Join Date: Feb 2014 Posts: 156

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11-11-2017, 10:02 AM	#7
jsmith294 Gone Wild Join Date: Feb 2014 Posts: 156	Re: Poopsie's on Bypass Sorry about the multitude of questions, but I am considering a similar upgrade for my 2003 series drive DS. The new controller looks like it will be exposed to road debris and puddle splash in its intended location. Are you going to use a shield? Is the controller water resistant? Thanks!
jsmith294 Gone Wild Join Date: Feb 2014 Posts: 156

11-11-2017, 03:56 PM	#9
fsu1tm Gone Wild Join Date: Jan 2015 Location: Seminole Country Posts: 836	Re: Poopsie's on Bypass I'm not changing out the motor right now. Saving that for a later project. Hoping that the upgrade will show the motor is OK.

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