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Unread 05-11-2014, 08:06 PM   #1
Not Yet Wild
 
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Default New forward/reverse switch sparking and burning

Hello, I'm rebuilding a 1995 Club Car DS 36-volt. I've hooked all he electrical back up and the new forward/reverse switch is sparking badly when I put it in the Forward position. I even saw flames briefly. Reverse seems to be fine - hear the buzzer and the cart moves just fine. Also noticed that it happens even with the key in the OFF position.

The cart as a new Solenoid and Front/rear controller. The charging port and controller are original. I suppose I could have hooked something up incorrectly, but I've been over the wiring diagram several times.

Any idea what could cause this? Bad key switch maybe? Needless to say, I've unhooked the batteries for the time being.

Thanks.
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Unread 05-11-2014, 08:56 PM   #2
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Default Re: New forward/reverse switch sparking and burning

Read through this thread > 84 DS Resistor Cart no clicking and no movement

There are some diagrams you can check your wiring against.
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Unread 05-12-2014, 12:30 PM   #3
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Default Re: New forward/reverse switch sparking and burning

I have the diagram from the Service Manual. I've checked several times. I'm just wondering if there is anything besides the wiring that would cause that.
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Unread 05-12-2014, 12:52 PM   #4
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Default Re: New forward/reverse switch sparking and burning

if it is sparking and on fire it would be crossed wires

here is your f/r switch with factory colors


Last edited by crash test dummy; 05-12-2014 at 04:27 PM.. Reason: re-labled diaram
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Unread 05-12-2014, 02:44 PM   #5
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Default Re: New forward/reverse switch sparking and burning

Quote:
Originally Posted by crash test dummy View Post
if it is sparking and on fire it would be crossed wires

here is your f/r switch with factory colors
Probably one of the most helpful diagrams I have seen yet....Crash , you da MAN!!!

EDIT:....wouldn't that be 88 -99 ? or how ever long they used it.....my 88 is just like that anyway...
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Unread 05-12-2014, 03:04 PM   #6
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Default Re: New forward/reverse switch sparking and burning

Quote:
Originally Posted by Budule View Post
Probably one of the most helpful diagrams I have seen yet....Crash , you da MAN!!!

EDIT:....wouldn't that be 88 -99 ? or how ever long they used it.....my 88 is just like that anyway...
as i have seen it (my 93) a few times

it really should be 86 ~ 03 36v v- glide ???
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Unread 05-12-2014, 03:59 PM   #7
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Default Re: New forward/reverse switch sparking and burning

I was under the impression that the vglide started in 88 and a half model year.....
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Unread 05-12-2014, 04:17 PM   #8
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Default Re: New forward/reverse switch sparking and burning

that sounds right
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Unread 05-12-2014, 04:59 PM   #9
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Default Re: New forward/reverse switch sparking and burning

Most all GC model year changes are made mid-year... Don't ask me why
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Unread 05-12-2014, 05:16 PM   #10
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Default Re: New forward/reverse switch sparking and burning

Quote:
Originally Posted by scottyb View Post
Most all GC model year changes are made mid-year... Don't ask me why
cause they start the new model year build then ... so they can sell the new model before the end of the year
like the 2015 mustang will be on sale in sept '14
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