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Unread 11-13-2013, 09:55 AM   #1
Gone Wild
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Default Help with rewiring during rebuild

I am rebuilding a 1993 Club Car DS with scotty b conversion kit. My main issue right now is that the prior electrical wiring was/is a mess. I have the battery cables from Scotty B and understand where those go. I have looked at the wiring diagram on the stickies, but it has very little information. Also, this cart has wiring not in the diagrams. Here are a few photos

Wiring 1.jpg

Wiring 2.jpg

Wiring 3.jpg

Right now, I am just trying to get the cart up and running so the lights are not critical. I realize that the first picture shows the key switch, but what is that other round thing with two wires?

Also, in the second picture, can anyone make any sense out of this mess? It had headlights, so I assume alot of that was for the headlights.

Also, what's this thing in the third picture?

I really am not as dumb as my questions seem to indicate. I have plenty of DIY experience wiring boats, car stereos, etc. with few problems, but usually you can tell exactly what's what there.

As I said, I am just focusing on getting her up and running right now, so just the basics would be a good place to start, including what type of wiring I need to replace the existing wiring with. That's one thing not on the diagram - what are the kinds of these wires.

Thanks so much.
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Unread 11-13-2013, 09:59 AM   #2
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Default Re: Help with rewiring during rebuild

Do yourself a favor and remove all the wiring from the cart and start fresh. The diagram you got with the conversion kit (below) has all the wiring you need to make the cart run. Lighting is extra. The black thing with wires coming out is a voltage reducer. It takes 16v in and puts 12v out. Not the best plan for 12v power.
Attached Images
File Type: jpg CC-Conversion-solenoid-activation-circuit_web.jpg (425.8 KB, 0 views)
File Type: jpg Club-Car-Series-cable-numbers(web).jpg (169.1 KB, 0 views)
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Unread 11-13-2013, 10:20 AM   #3
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Default Re: Help with rewiring during rebuild

Thanks, Scotty. I will just take everything out. Can you tell me what type, color, gauge, strand for the non-numbered wires in your diagram I should use? Thanks so much.
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Unread 11-14-2013, 01:04 PM   #4
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Default Re: Help with rewiring during rebuild

And another question for scottyb or anyone - what size crimps, etc. go on the various terminals? hard to tell from diagram. Thanks.
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Unread 11-14-2013, 01:13 PM   #5
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Default Re: Help with rewiring during rebuild

not to argue with scotty but .. the box in photo 3 is the factory fuse box for the lights ,horn,brakes, etc... you take off cover you will see the fuses
if you need help with the wiring for lights and stuff behind the dash let me know as i have the same set up
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Unread 11-14-2013, 09:32 PM   #6
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Default Re: Help with rewiring during rebuild

I do need help actually. The wiring for the lights looks ok, but old. I think I may just remove it all. what do you think? I am definitely removing all the wires that scottyb identified. My only question is why there are these tabs for wire connectors behind the key switch. I don't know if you can see them in the picture. What are those for? In scotty's diagram, they are not used. Do you use yours? If so, what for? Thanks for the help. I can wire as long as I know what I need to hook it up to!
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Unread 11-14-2013, 10:10 PM   #7
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Default Re: Help with rewiring during rebuild

frist question , do you have a micro switch under cart by the brake pedal ? or a block attached to the back of the brake pedal ?

here is first photo with notes
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Unread 11-15-2013, 09:52 AM   #8
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Default Re: Help with rewiring during rebuild

I dunno. Will check after work. Thanks again.
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