G2 Speed Controller Excessive Heat

[talahips]

New to the site so here we go. Found a deal on 36V G2 recently that essentially had new batteries. The cart does not have much speed or torque. Decided to take the speed controller out and clean all the connections and copper contacts. Put a new contact on the controller arm (part of it was missing). Put it back in the cart and it took off with much better speed. Then the problem. The plastic controller arm got so hot it melted in half at the connection to the contact. So I'm thinking maybe there is way to much resistance in the controller. Only thing unusual I noticed was a couple of the bolts that hold the contacts on the board were steel and did not match what appears to be the original copper bolts (don't know this has anything to so with the problem). Anyone had this problem or any advice?:

[cgtech]

Alignment between moving contact & stationary contacts is critical. The moving one must sit PERFECTLY flat on the stationary ones.

[talahips]

I don't see any adjustments for alignment other than tension on the controller arm spring. This would allow some vertical or top to bottom adjustment but none in the other direction. It seems if was off some, it should still not get hot enough to melt the arm in half! Thanks.