91 club car burning wires

[bugkiller86]

I have a 91 cc and the A2 wire is getting so hot its burning the coating off and making the battery wires extremely hot. What could be causing this? New wires and batteries! Thanks!

[OLD MEC]

Were you having this problem BEFORE you changed batterys and stock 6 guage cables? What type and guage of cables and connection lugs did you use as replacements as this could be part of problem? Sounds like you may possibly have a bad connection inside motor at A-2 post? Is the insulation burning next to motor post, or near resistor coil connection or over whole A-2 wire? Heat normally is caused by loose or high resistance in connections or wire itself and since you have replaced wires that shouldnt be problem?

[bugkiller86]

I replaced wires with 4 gauge wires and it is melting on the resistor side of the wire. If I have a problem in the motor can it be fixed or do I need a motor? When I got the cart it didnt have batteries. It has standard battery lugs.

[OLD MEC]

Were your wires a aftermarket kit or did you make your own? If you made your own cables what kind of cable did you use ( multi strand welding cable 400-600 count ) or anything else? Also did you cripp ends on cables or solder them on, or better yet BOTH?
I still refer back to my original that heat is caused by loose or for some reason high resistance ( like poor cable to end connections ).
To answer your question YES you can have your motor repaired by any motor repair shop that will work on cart motors ( some wont as they know they are run harder than normal motors )?

[bugkiller86]

Crimped ends and I made my own. 4 gauge welding wire is what I used. The resistor looks rusted could that be a big problem?

[OLD MEC]

As long as the resistor coils are not cracked or broken you are OK. When you replaced the cables did you disassemble resistors to plastic board and clean all contacts shiny clean and tighten good and tight? The rust is from all the heat that they creat when running at slower speeds. If you ever have seat off and drive at night you can see how hot they get, in fact if you look under cart at night you will notice light coming from underneath, almost like what the LED lights that they put on cars, bikes, and carts. They can get to almost red-white in color at times when slow speed or when pulling hills etc.
I used to crimp and then solder all cable ends, then install shrink tubing and spray all exposed metal with battery terminal protection just to be sure, later I found a local welding supply shop that if I bought cable and ends from them they would crimp with a hydraulic crimper much better than any I could have done, and I add shrink and spray to finish them off?

[bugkiller86]

Thanks Ill clean all resisotor connections to day. And see how that goes. Thanks

[shadowman]

man i saw a set on an older E-Z go get so hot they started a fire.....................................

[bugkiller86]

Yea we dont want no fire... Some heat is ok but no fire...

[OLD MEC]

YA Just like when first police cars came out with catalytic converters and because of radio's had to leave engines running in dry grass?