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Old 05-03-2009, 10:18 PM   #1
allen2
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Default Installing potentiometer in 1991 XI 875

I purchased a 1991 EZ-GO model XI 875 Workhorse (series system?) from Boeing Surplus. It appears to be all there except for the potentiometer. I purchased a new one but cannot make sense of the wires. I do have a series system wiring schematic, thanks to roady 89.
The loose wires I have at the mounting site are: a brown and a white both with male ends that appear to go towards the controller, 2 orange with female ends where one seems to go back to the controller and the other goes forward and then there is one yellow wire with an enclosed, screw down end.
The new potentiometer I have lines up perfectly with the mounting holes and has: a black wire with a male end, a white wire with a female end and then there are three terminals on the micro-switch which look likes it takes a female plug.
It appears that I have the right number of wires and I suspect the black and white = the brown and white but the other three have me stumped.
I have looked over the wiring diagram I have but things do not seem to add up. It may be very simple but I am not very adept at electronics.
Anyone have any ideas as to which wire goes where?
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Old 05-03-2009, 10:31 PM   #2
scottyb
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Default Re: Installing potentiometer in 1991 XI 875

You have 2 units in one there a potentiometer which has a black and white wire.... you can check them with your ohm meter to verify they are putting out 0-5K ohms when the throttle is activated. (This is a good idea so later on you won't have less then full throttle and wonder why)
The 2nd thing is a micro switch which is suppose to activate at the first movement of the throttle or pot lever...the 3 connections are Common = connect to system power in usually from the key or the F&R micro switch? Either works okay. NC and NO = Normally closed and Normally Open...Connect from Normally Closed to the power on for the controller. Hope this helps
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Old 05-03-2009, 10:40 PM   #3
allen2
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Default Re: Installing potentiometer in 1991 XI 875

Thanks scottyb, that does help some. The problem I still have is that the terminals on my micro-switch are not marked. They are brass prongs and come out of the end of the micro-switch and are less than 1/4" apart. It is a Curtis PB-6.
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Old 05-03-2009, 10:50 PM   #4
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Default Re: Installing potentiometer in 1991 XI 875

YOu mean 1 micro with 2 terminals? If so it is a standard on/off switch. Check it with your voltnmeter. There is no right and wrong way to wire it....power in /power out ..... or not. ON n OFF
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Old 05-03-2009, 10:56 PM   #5
allen2
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Default Re: Installing potentiometer in 1991 XI 875

No, one micro-switch with three terminals, unmarked. The wires that appear to go to it are: two orange, with female ends, one going forward (towards key?) and one going to the rear (to controller?) the other is a yellow wire with an enclosed, screw down end that goes forward (to key or F/R?)
I must admit I have not completely traced where these wires go.
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Old 05-03-2009, 11:07 PM   #6
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Default Re: Installing potentiometer in 1991 XI 875

..... and that is not making it any easier from here You have a diagram and a voltmeter? test the switch probably 1 power in and 2 power out. If it is the micro activated by putting the lever in to reverse the reverse buzzer is the other wire ..... start doing some homework and use masking tape and a pen until they are all IDed ...
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Old 05-03-2009, 11:16 PM   #7
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Default Re: Installing potentiometer in 1991 XI 875

I am sure that is good advice and I will probably have to eventually tackle it in that manner. I was hoping for a more straightforward solution. BTW, there is no potentiometer in it and one of the batteries (all dead) is isolated (cables removed) and the reverse signal still works. Talk about confusing.
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Old 05-03-2009, 11:31 PM   #8
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Default Re: Installing potentiometer in 1991 XI 875

start with the basics .... it is not a very complicated system.... if you get stuck we will be here. Good luck
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Old 05-03-2009, 11:34 PM   #9
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Default Re: Installing potentiometer in 1991 XI 875

OK, thanks for the help scotty
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