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Unread 04-22-2009, 08:24 AM   #1
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Cool Broken Cable

I was driving my Electric Club Car, stopped to load it, jumped back in and put it in reverse and moved back into forward and the car was dead. I couldn't figure it out. I still had the annoying reverse buzzer but that was all. 3 days later I was about to tear into the wires to ring out and found that one of the cables to my motor was separated from the terminal lug. I inspected the cable and saw that half of the wires where fresh copper and the other half had signs of corrosion like it had been broken for a while already. Now my question to the wise ones. Will switching from reverse to forward drive before the car is stopped send a current so strong to the motor that it might short the cable in two? I thought maybe so because only half of the cable was actually still in tack and the remaining cable that was connected could not hold the current. Any thoughts, advice or comments are welcome.

Thank you
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Unread 04-22-2009, 09:51 AM   #2
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Default Re: Broken Cable

It sounds as if you have the old gremlin CORROSION that gives us all problems. Replace the complete cable and while your at it check ALL of your other cables as you may have more going bad? The up and down motion of the motor while moving causes the cables to fail and possibly when you changed directions there was enough movement to snap the already weak cable off?
The only way you could damage a cable is if you have a LIFTED cart and sometimes this will require longer cables, as the motor and differential is further away from frame?
If you are thinking of adding any upgrades to your cart, this might be the time to upgrade your cables to 4 guage welding cables while your doing a replacement?
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Unread 04-22-2009, 05:03 PM   #3
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Default Re: Broken Cable

Very good advice OLD MEC, it did look like it might had been rocking around some and wearing. I will replace the old cable with a new longer and heavier gage of cable. I am a Aircraft Mechanic by trade, so I deal with corrosion all the time. This is my first Club Car. I got it for a great deal and now I want to go through it and replace the existing cables and connector nuts and bolts and upgrade it...basically overhaul an already well running Cart, there is surface corrosion throughout the car. I learned from Sticky how to identify my Club Car model now I want to find a place I can buy a user manual or parts manual for my Car, any suggestion?
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Unread 04-22-2009, 05:11 PM   #4
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Default Re: Broken Cable

For an on line Club Car parts catalog go to the following site

http://www.golfcartsonline.com/parts/

Check with sponsors above for other manuals needed
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Unread 04-22-2009, 05:22 PM   #5
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Default Re: Broken Cable

I really dont have to give you any advise on aluminum parts etc. Im sure you could give an OLD RETIRED AUTO AND TRUCK MECHANIC LOTS of advise on vibration and motion problems.
I like the aluminum frame on Club Car for that reason and couldnt think of a better place to use the metal. It has and does crack on the older models before the supplier of frames went computer controlled. Im not sure what year that new company took over building frames?
Good luck I think you will like it more and more over time, only weak point I find is OBC used because of Charger? I would like to use a automatic charger or a timer type charger rather than an expensive OBC to control.
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Unread 04-23-2009, 01:50 PM   #6
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Default Re: Broken Cable

don,t make the cable any longer than needed, make sure you disconnect main power before getting in there with a wrench and tape most of the wrench up so if it does touch something you don,t cause yourself more problems.............while your in there check and either replace or clean all cable connections............if one was bad like that there may be more to follow.............................
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