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Unread 10-08-2019, 04:51 PM   #1
Not Yet Wild
 
Join Date: Mar 2018
Posts: 3
Default Club car da wire getting hot

I have an 04 club car ds the orange wire from the forward reverse switch to the motor is getting really hot and then the cart will start to slow till I have no power when the wire cools off it will run again only for a few minutes
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Unread 10-08-2019, 07:07 PM   #2
Getting Wild
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Join Date: Aug 2016
Location: Illinois
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Default Re: Club car da wire getting hot

Sounds like you have a bad cable. Likely has internal resistance. Possibly a bad connection at either end of the cable. I would replace the cable and see if it improves. I would expect the rest of the cables to be of similar age and condition and could benefit from replacement as well.

If you wanted to test before replacement, connect volt meter at both ends and drive it. If the cable is okay, you should see close to 0 volts. If high internal resistance in the cable, then you should see some voltage on the volt meter display. I would prefer this voltage drop testing while driving the cart to load the circuit, but raising the drive wheels off the ground should work.

Or you could flip the switch to tow and remove the cable. Check resistance from one end of the cable to the other with an ohm meter. I would expect less than 1ohm. I do not prefer this test as it may not be as reliable as testing the circuit live and loaded.

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Unread 10-09-2019, 12:49 PM   #3
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Join Date: Mar 2018
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Default Re: Club car da wire getting hot

I took the wire off from the screw on top of the motor now the screw won’t tighten down onto the motor it just keeps turning did I break something taking wire off
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Unread 10-09-2019, 01:47 PM   #4
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Location: Charlotte, NC
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Default Re: Club car da wire getting hot

I am afraid so, You always need to use two wrenches on any Motor posts, one on the bottom nut against the motor to prevent the post from turning and one on the top nut to loosen the top nut.

The OEM Orange cable connects to one of the field wires inside the motor and that wire is spot welded to the end of the stud.

You will need a new or used motor unless you find a Motor repair shop near by that can fix that for you for a reasonable cost.
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Unread 10-09-2019, 07:18 PM   #5
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Join Date: Dec 2011
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Default Re: Club car da wire getting hot

Not hard to do if you don't do it much. I almost did that on mine to clean the connectors. Not sure how much I turned mine before I caught it, maybe half a turn, or how much it takes to break the wire off.
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