97 club car 48v basket case project

[FullSpool]

It's a 2 row plug and 5 wires on the f/r switch .
It came with a conversion harness to go from 2 row to 3 row plug so it will fit in the FSIP controller.

Thanks for the info guys , will test more.

[FullSpool]

I grounded the yellow wire from OBC and it still doesnt run.

I check the ohms on the wires sergo suggested and its avg 5k throughout the range so I don't think it's seeing a throttle signal.

video below

https://www.youtube.com/watch?v=6Zam5mFzE-o

[Sergio]

Originally Posted by FullSpool

I grounded the yellow wire from OBC and it still doesnt run.

You need to run the yellow wire from Controller to negative.

Your throttle signal as posted would not allow the cart to run at all.

Did You measure the resistance between White and Purple wires at the Multi-Step Potentiometer?

It should be a fixed value and not change as You press the pedal.

[FullSpool]

Grounded the yellow wire from controller and measured
ohms from purple and white .

at rest position 5485 ohms
at WOT 5485 ohms

[Sergio]

Those readings are good, but back in post #13 you said:

2. measures 0 at stop scales up to 4.9k ohms , then 0 at full throttle.

That second 0 is a problem, maybe the Multi-Step arm is not aligned properly and it is separating from the pads at the end.


Can You measure it again but this time between the Yellow and Purple wires?

You should see it range from 5.5kΩ to 0Ω (not 0L).

Make sure you keep one of the rear wheels off the ground for safety.


Measure theses voltages on the harness side of the Multi-Step potentiometer.

Measure the voltage from the purple wire (meter negative probe) and pack positive battery post.

You should get +48v (actual pack voltage).

With the Key switch ON and the FNR in Forward, measure the voltage from the purple wire (meter negative probe) and the white/black wire.

You should get more than 5v.

[FullSpool]

Originally Posted by Sergio

Those readings are good, but back in post #13 you said:


That second 0 is a problem, maybe the Multi-Step arm is not aligned properly and it is separating from the pads at the end.

I used alligator clips this time, think my first reading I moved alittle

Can You measure it again but this time between the Yellow and Purple wires?

You should see it range from 5.5kΩ to 0Ω (not 0L).

I took the switch off and made a video for you
https://www.youtube.com/watch?v=_TnhCKcYsxk

Make sure you keep one of the rear wheels off the ground for safety.


Measure theses voltages on the harness side of the Multi-Step potentiometer.

Measure the voltage from the purple wire (meter negative probe) and pack positive battery post.

You should get +48v (actual pack voltage).

I measured 49.2v
With the Key switch ON and the FNR in Forward, measure the voltage from the purple wire (meter negative probe) and the white/black wire.

You should get more than 5v.

when I do this it reads 0 volts

[Sergio]

That Regen-1 system was one the most problematic designs that Club Car ever came up with, and when you add an unknow conversion on top of it, it may be a lost cause.

But just in case, I forgot the Regen-1 used the throttle in a different manner than other systems, specifically how the "Top" and "Bottom" of the throttle ranges are defined.

Your last video clearly shows Your 3-wire Multi-Step potentiometer is correctly wired according to the system that use it for a throttle.

The short lived Regen-1 as far as I know did not have a Multi-Step potentiometer option and it used the wire colors differently.

Try swapping the White/black stripe with the purple wires at the Multi-Step potentiometer and try again.

[FullSpool]

just so I am clear I am repinning the plug so white black on the pot plug ties to purple on the harness and purple on the pot plug ties into white/black on the harness.Then I am adding power to the system to see if it works?

[FullSpool]

So I swapped the purple and white/black wire and now the small post on my solenoid have zero voltage but the large to post have 48 volts. Now on my motor A1 and a2 have 47 volts to them and F1 and F2 have 1.6 volts.

However I hear no solenoid clicking nor does the motor turn.

[Sergio]

Sorry but I am out of ideas on this one...

The best solution for those Regen-1 carts is typically to install a complete IQ harness and change the controller.