Wire from FNR switch to motor very hot

[OrtegaOyster]

Newbie here. My new to me 1997 Club Car DS Fairway villager is great. However the wire (orange) from the FNR to the motor gets EXTREMELY hot. I replaced the FNR switch (probably didn't have to as the one i replaced looked fine) and I cleaned all of the connections with lectric cleaner and wire brush. The wires on this cart appear to be original but would have been appropriate from the factory. I have added 3" lift and 20x10x10 tires but the wire was getting hot before I added those. I also purchased a "HD" solenoid but again wouldn't it have had the appropriate solenoid from the factory? Any insight would be greatly appreciated. Thanks!

[camaroluvz28]

I would replace all of the factory wiring with at least 4 gauge to compensate for the larger wheels and tires...especially considering the original wiring is over 20 years old by now...there may be corrosion inside the insulation causing this issue...or the motor brushes may be worn or the motor could be dirty internally causing heat build-up. Just some things that come to mind.

[OrtegaOyster]

Thanks so much, I have already ordered 4ga wire for replacement and will be replacing the solenoid with a HD version. That being said I get no click at all from the current solenoid (appears to be original) but the cart still runs? Also, if there is dust in the motor how do you remedy that and from a difficulty perspective should I try the other remedies first before getting into the motor?

[camaroluvz28]

Yeah I would get the wiring done and the solenoid on and see what happens from there...solenoid not clicking but running may point to it being welded open or another issue but since you've got one on the way we can deal with that after install...sorry was out for the last few days..