Any tips for replacing all the power wires?

Mrjonman

Got my 2 guage wires in the mail today, obviously the battery connections are easy but just wanted to check and see if there were any other tips or tricks?

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BGW

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kernal

Put run/tow switch in tow if you have one. Do one wire at a time. Double check connections. Be careful about dropping wrenches on batteries (wrap handles with tape). Use two wrenches on motor connections. Could be expensive if you ignore this. On batteries put large wires on bottom of the connection with small wires on top where applicable. Don't over tighten bolts on batteries. 110=115 [I]inch[I]pounds I think. (inch pounds not foot pounds). Use dielectric grease, vasoline or battery connection protectorate spray. All I can think of at the moment.

Mrjonman

Forgot to mention, it's a 2003 txt so no run tow switch

DaveTM

#1--The very first thing you need to do is disconnect the positive battery heavy duty battery wire that runs from the battery to either your solenoid or your controller. (Which ever that "last" positive battery terminal lead goes to.) I would disconnect this wire at both ends and remove it from the cart so that it minimizes any chance of you having an accidental short.

#2--Tape up (Duct Tape will work) one end of any box wrench your going to use while in the battery work area. It's easy to drop a wrench, or accidentally hit a pos and neg terminal at the same time with your longer wrenches. Bad things can happen if this occurs.....and sometimes these are expensive bad things.

#3--Follow the above advice of replace one wire at a time. Also, you may want to take a cell phone picture...close up....of your wiring around the solenoid and controller before you start. You know.....stuff happens.

Dave

Mrjonman

Does it make it drastically easier if I remove the body or should it be no big deal as is?

DaveTM

No. I wouldn't do that. You should however, remove the rear tires\wheels. Jack up the cart and place the axle on jack stands. Remember, DO NOT "floor" the peddle when your all done to watch the axle spin like crazy. This could likely cause your motor to over-rev and likely just spin right apart....thus costing you a new motor.

But, removing the rear tires\wheels will give you easier access to the motor bolts (on the driver side) and easier access to zip tying up the heavy gauge wires at the corner of the battery box on the passenger side, and zip tying them up at the edge of the motor.

Mrjonman

Thanks!