2004 DS F/R Switch Wire Gets Hot

[Njjacobs]

Hi all. After even short drives, my F/R wired that are orange and blue get very hot to the touch. How do I know if I need to upgrade to bigger wires, upgraded to HD F/R switch, or both? My 5 battery cables have been upgraded to 4 gauge if that matters. Thanks for any help!

[Margaritaville]

I assume this is Series Club Car. If it has a lever F&R (not a toggle) with cables (Not just wires) running to it. If so it’s a series cart. If it’s stock and there aren’t other issues, they shouldn’t be hot. However, if you upgraded any portion of the cables you want to do ALL of them. The batteries are just a portion of the circuit. Cables to switch, solenoid, controller, and motor all need to be done. Not sure, but you may have decreased resistance in other parts of the circuit and the switch cables are hot because you’ve transferred the resistance there. Just a guess.

[Njjacobs]

Yes it is a series. The motor is upgraded to a higher speed motor that is supposed to be ok to run on stock controller. I had an authorized club car dealer so the motor swap and the only cables they upgraded were the 5 battery cables to 4gauge. Should I stay with the 4gauge if I upgrade others or can I go ahead and do 2gauge?

[Swan]

With a stock controller you really dont need any bigger the 4ga , but need to do them all. If you see yourself later upgrading the controller then you may want to go to 2ga. If you make them yourself it takes roughly 29 feet of cable to do them all. Also you may want to look at doing the obc pass through bolt kit (can be found at Scottyb's cartsunlimited.net ) some 4ga will fit though it but 2ga wont.

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