help with 92 club car ds

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Guess I will have too put 1 at a time up

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Hope this does it for ya

[Beccalynn]

Sorry its been so long was having some major problems but all is well now, but for some reason I cannot upload pics I'll keep trying though

[Beccalynn]

Ok here's the latest on the cart it will go forward and spark in reverse has a new switch on it, but the motor wiring we believe is where the problems are at, we have found melted wires

[Beccalynn]

ok finally got it!!

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Originally Posted by Beccalynn

Ok here's the latest on the cart it will go forward and spark in reverse has a new switch on it, but the motor wiring we believe is where the problems are at, we have found melted wires

Here's another diagram and if you have a melted wire it could be from a loose connection or a bad terminal at the ends of the wire.... Now with that being said it looks like that's the factory wiring and way over due to be replaced.... That was 1 of the first things I did when I got my cart.... Shop around and you can find 4 gage wire pretty cheap and at napa auto parts store I got the terminals, you will need a torche, rosin automotive solder and heat shrink, I replaced all batt cables and cables on fnr switch... I didn't replace wires going to or from resistor coil and cart did fine.... Also if your planning on major upgrades in the future mite wanna go with 2 gage instead of 4gage

[Scott H.]

Here's part of your problem:



Notice the gap between the bolt and the connector? That's NOT supposed to be there! You have a small contact area for the needed power to go through and the electricity is jumping the gap.

Look at the one on the white cable, you'll see the connector you need.

Please don't try and put washers on it to solve the problem, the gap in the connector will still be there and you still will not be getting the correct power to the system.

Either have the connector replaced with the correct one or purchase a new cable (hopefully from one of the site supporters) to correct the problem and restore full power to the system.

*EDIT*

I just downloaded the photos and enlarged them on my computer. It looks like who ever replaced the cables (the new looking ones) used Automotive grade cable to make them. If they did, you need to replace them once again with Welding Cable or with a new cable kit from a GOLF CART parts store.

Automotive cable does not have the connectivity that welding cable does, causes high resistance, and high heat build up in the cables. In a 12 Volt Automotive system, those cables will work fine, but when you run 36 Volts (like you are) or 48 Volts (like other carts), they fail miserably.

Look at the cable end on the white wire, it has a high strand count. That is what you need for powering the cart.

Also, taking the wires off the motor one at a time so you don't mix them up (with the battery pack disconnected for safety) and cleaning the connectors and the terminals wouldn't be a bad idea.

I hope this helps,
-Scott H.

[Beccalynn]

thank u so much!! i will certainly be doing that!!!