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Unread 04-30-2018, 02:51 PM   #1
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Join Date: Mar 2016
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Default Am I going to break my Caroche if....

I have a 1980 Club Car Caroche. She is a beauty, but certainly not without her problems.

(I apologize in advance for calling everything thingsmabobs and doohickeys. I am a noobie.)

There is a 4 gauge cable running from the engine (I assume it's the engine? Big round thing behind all the batteries and stuff?) to a big coil behind the solenoids (I know what those are thanks to this forum!).

What is this coil called? What is its purpose?

I ask because the end of the 4 gauge wire connecting to it corroded and then broke, and the resulting arcs melted the outside of the cable. Yikes!

Well when trying to replace that, I cannot for the life of me disconnect that screw that holds big coil to the top of the metal piece coming off of the passenger side solenoid.

Which gets to my main question: will I blow up my beloved 1980 Club Car Caroche if I connect a new cable to the bottom of that metal piece (essentially the top of the solenoid) RATHER than to the top of the metal piece/base of that big coil?

Thanks in advance for all of your help!
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Unread 05-07-2018, 09:26 AM   #2
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Default Re: Am I going to break my Caroche if....

I am still hoping someone can answer my questions about that coil.

I drove it around a little bit this weekend. I drove a fair ways, and then all of the sudden, lose power for a few seconds. Then you hit the gas, and it comes right back to life.

Am I going to break my Caroche wiring it this way?
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Unread 05-07-2018, 09:59 AM   #3
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Default Re: Am I going to break my Caroche if....

Lol! That is the electric motor behind the batteries and I beleive you are referring to the resistor coil or coil bank if you have multiple.

Please take a picture of the issue you have and post it for us to see and comment upon.

Also, Aflyer is in the middle of a Caroche rebuild and would be a good resource for you to reach out to. You can PM him from your User CP or the top left side of the screen that says Private Messages.
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Unread 05-07-2018, 11:36 AM   #4
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Default Re: Am I going to break my Caroche if....

I will snap some pics this weekend and post them next week.
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Unread 05-15-2018, 08:58 AM   #5
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Default Re: Am I going to break my Caroche if....

As promised, pictures.

The first of course is of my baby!

The second picture is what I am talking about. In the foreground part of the coil, you will kind of see at the top where the old cable broke off, and where I attached the new cable at the bottom.
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Unread 05-15-2018, 11:29 AM   #6
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Default Re: Am I going to break my Caroche if....

Looking GOOD!
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Unread 05-15-2018, 01:50 PM   #7
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Default Re: Am I going to break my Caroche if....

i know little about golf cart, but a lot about electricity
if the connection where the cable corroded is loose (it looks loose) the connection will heat up
even the corrosion on the rusty connection will create impedance and thus heat
the bolt isn't anything special, you should be able to snap and remove the bolt with 2 box wrenches
clean up the ends and replace the bolt

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Unread 05-15-2018, 02:20 PM   #8
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Default Re: Am I going to break my Caroche if....

The way you have that wired will work just fine but you may want to clean things up a bit.

That "coil" you speak of is the resistor bank which was the most common form of speed control on early electric carts. The way they work is simple.....the more coils (resistance) your current goes through the more current gets held back thus preventing it from getting to the motor. The less current that gets to the motor the slower is goes. All those wires attached to that coil are each for different speeds given that where they are attached to the coil will cause different resistances. I can tell you have a 4 speed cart (maybe 5 if it has an unresisted circuit but I can't see it in your pic) just by looking at it.

Guys have been known to remove some of those coils which will make the cart go faster. I don't advise that, though. That cart is coming up on 40 years old. It's big $$$ if you screw the motor up.
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Unread 05-15-2018, 02:21 PM   #9
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Default Re: Am I going to break my Caroche if....

That cable should have never been connected to the top of that bracket.

The correct place is where you have it now, directly on top of the Solenoid.

When You were at WOT (Wide Open Throttle), the max current would have traveled through the bracket to the Solenoid and that was adding unnecessary resistance and heat to the current path.
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Unread 05-16-2018, 08:41 AM   #10
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Default Re: Am I going to break my Caroche if....

This is extremely helpful advice, and good to know I have now hooked it up correctly when it was previously incorrect.

I will see if I can snap out that bolt and get a new one installed. When you look at this picture closeup, you are correct. It does appear loose, and should be replaced.

It is a 4 speed cart (I learned all about that when I started having to replace solenoids for the first time. Many thanks again to this forum!).

Thanks everyone!
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