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Unread 06-04-2015, 10:09 PM   #21
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Default re: 1968 Harley-Davidson DE

After I looked at the diagram I realized Harley REALLY overcomplicated the design of the resistor components!

Almost like the parent company was trying to build a nuclear reactor in there. Oh, wait.....
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Unread 06-06-2015, 12:09 AM   #22
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Default re: 1968 Harley-Davidson DE

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Originally Posted by 93yellowclubcar View Post
After I looked at the diagram I realized Harley REALLY overcomplicated the design of the resistor components!

Almost like the parent company was trying to build a nuclear reactor in there. Oh, wait.....
Boy did they ever!

I have determined that there was excessive resistance in the 36v half of the circuit. At the charge point, I was only getting 0.9v, where it should read 36v. That explains why the charger wasn't charging.

Right now I have all the wiring taken out of the cart and am cleaning each and every connection and wire terminal. I am really hoping she runs right after all this.

While I have all the wiring out, I figured I'd replace the battery trays (they needed it, the PO had put license plates under the batteries!).

I replaced the trays with aluminum angle. Will I have an issue since the frame is steel? I didn't think of this till after the install.

I charged each of the batteries individually. All but one charged up, and the sick one is only putting out 4v. I may try to find a used one in similar condition to the rest to replace it with.

That's it for now, next up is putting all the wiring back together and crossing my fingers...
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Unread 06-06-2015, 12:10 AM   #23
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Default re: 1968 Harley-Davidson DE

New tray
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Unread 06-10-2015, 07:04 PM   #24
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Default re: 1968 Harley-Davidson DE

This thing has got me pulling my hair out...
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Unread 06-10-2015, 08:04 PM   #25
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Default re: 1968 Harley-Davidson DE

Awesome looking cart Jake!

Have you considered upgrading to a controller? It would be a lot easier to wire.
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Unread 06-10-2015, 08:26 PM   #26
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Default re: 1968 Harley-Davidson DE

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Originally Posted by jakesnake27 View Post
This thing has got me pulling my hair out...
You're in deep.
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Unread 06-10-2015, 10:21 PM   #27
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Default re: 1968 Harley-Davidson DE

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Awesome looking cart Jake!

Have you considered upgrading to a controller? It would be a lot easier to wire.
Thanks Man. I just wish it ran as good as it looked!

I have, but I'm not sure I want to put that much money into it. I'm considering putting CC resistor components in it to simplify things a bit.
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Unread 06-10-2015, 10:22 PM   #28
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Default re: 1968 Harley-Davidson DE

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You're in deep.
Yeah, real deep...
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Unread 06-16-2015, 09:29 PM   #29
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Default re: 1968 Harley-Davidson DE

Boy do I feel dumb.

I jumped five of my CC batteries (40v) just for the heck of it. The thing ran like a bat out of he*l. All speeds worked great.

Batteries were my issue the entire time. I will be purchasing new ones soon.
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Unread 06-16-2015, 10:26 PM   #30
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Default re: 1968 Harley-Davidson DE

Seems like no matter the drive system of the age of these things most cart issues are the stupid batteries. Glad you got it figured out.
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