Buggies Gone Wild Golf Cart Forum - View Single Post - 2002 Club Car DS just stopped after installing 2 gauge wires

Sergio · 10-13-2015, 07:54 AM

The micro switch for the interlock is that first one closer to the front of the cart.

On your way home stop at the auto-parts store and pick up a can of CRC electronic contact cleaner.

Spray all over your FNR and micro switches to clean it up and remove oxidation.

Wait a few minutes for it to evaporate as it is flamable and a spark from the FNR can give you a surprise.

You should also spray inside the Multi-Step potentiometer if you end up having to open it.

Your cables don't look too good, but good news is that they don't work on looks.

After You get the cart working, drive it for at least 10 to 20 minutes, make sure You drive it at full speed near the end (so the current is the same through all of the high current cables), stop and immediately start feeling all cable ends near the lugs.

It is normal for them to feel a little warm, but what you are trying to feel is a cable end that is considerably warmer than the rest.

That is an indication of a poor connection that has developed excessive resistance.

If that is the case, replace all of the cables (4ga for stock or larger if You are planning on upgrading to a 500amp or more controller).

10-13-2015, 07:54 AM	#22
Sergio Gone Wild Join Date: Sep 2012 Location: Charlotte, NC Posts: 9,329	Re: 2002 Club Car DS just stopped after installing 2 gauge wires The micro switch for the interlock is that first one closer to the front of the cart. On your way home stop at the auto-parts store and pick up a can of CRC electronic contact cleaner. Spray all over your FNR and micro switches to clean it up and remove oxidation. Wait a few minutes for it to evaporate as it is flamable and a spark from the FNR can give you a surprise. You should also spray inside the Multi-Step potentiometer if you end up having to open it. Your cables don't look too good, but good news is that they don't work on looks. After You get the cart working, drive it for at least 10 to 20 minutes, make sure You drive it at full speed near the end (so the current is the same through all of the high current cables), stop and immediately start feeling all cable ends near the lugs. It is normal for them to feel a little warm, but what you are trying to feel is a cable end that is considerably warmer than the rest. That is an indication of a poor connection that has developed excessive resistance. If that is the case, replace all of the cables (4ga for stock or larger if You are planning on upgrading to a 500amp or more controller).