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Old 04-06-2021, 04:17 PM   #1
TdoubleD
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Default 2004 DS throttle finally clicks after 50%

Hi I am new to the golf cart game but now have a 2004 Club Car DS that used to be the old security cart for the Miami Herald (historical local newspaper). It was in not the best shape but after some new batteries, grease and a little repair here and there it gets the job done. While working on cleaning it up O noticed it had a Purple Plum Quick refurbished motor which made me happy. But after brand new Trojans and changing to 2g welding wire I only get 17mph out of the cart. I have recently noticed that the throttle does not engage or click until it is about 50% compressed. What are my options on figuring out how to get full throttle? Thank you for all the advice in advance.
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Old 04-07-2021, 04:24 AM   #2
movin-on
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Default Re: 2004 DS throttle finally clicks after 50%

Probably worn linkage...You should hear the mcor microswitch (not the solenoid) click after about an inch or so of pedal travel. You can try putting a wire tie or a piece of 1/4 inch hose around the drive bar where the pedal contacts it to make up for the wear...Look where the pedal contacts the bar and you will see what I mean...
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Old 04-07-2021, 07:51 AM   #3
TahoeDawgZ71
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Default Re: 2004 DS throttle finally clicks after 50%

As mentioned above, it's a worn pedal linkage. You can fix it by replacing the worn parts or you can try the fuel hose trick on the drive bar unless it's worn so badly that the park brake fails to lock nice and tight. If you want to replace the worn components you'll need a pivot rod and a set of accelerator bearing and bracket assemblies.

Qty 1 - 102026001 Pivot Rod
Qty 2 - 1011694 Accelerator Bearing And Bracket Assy
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Old 04-07-2021, 09:49 AM   #4
simicrintz
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Default Re: 2004 DS throttle finally clicks after 50%

Quote:
Originally Posted by TahoeDawgZ71 View Post
As mentioned above, it's a worn pedal linkage. You can fix it by replacing the worn parts or you can try the fuel hose trick on the drive bar unless it's worn so badly that the park brake fails to lock nice and tight. If you want to replace the worn components you'll need a pivot rod and a set of accelerator bearing and bracket assemblies.

Qty 1 - 102026001 Pivot Rod
Qty 2 - 1011694 Accelerator Bearing And Bracket Assy
Hijacking a bit but may be helpful: I have replaced these parts and am still unable to get full pedal (and have used the hose trick in conjunction)-any other thoughts/suggestions?
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Old 04-07-2021, 10:48 AM   #5
movin-on
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Default Re: 2004 DS throttle finally clicks after 50%

Quote:
Originally Posted by simicrintz View Post
Hijacking a bit but may be helpful: I have replaced these parts and am still unable to get full pedal (and have used the hose trick in conjunction)-any other thoughts/suggestions?
Have you tried a new mcor...
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Old 04-07-2021, 11:17 AM   #6
emoney
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Default Re: 2004 DS throttle finally clicks after 50%

If you have to replace the MCOR, look at the RTS. It's an adjustable MCOR and it even comes in the Version1. It ain't cheap, but well made

https://www.extremekartz.com/rts-mco...r-club-car-ds/
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Old 04-07-2021, 12:04 PM   #7
TahoeDawgZ71
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Default Re: 2004 DS throttle finally clicks after 50%

Quote:
Originally Posted by simicrintz View Post
Hijacking a bit but may be helpful: I have replaced these parts and am still unable to get full pedal (and have used the hose trick in conjunction)-any other thoughts/suggestions?
Bad MCOR, Worn Drive-Bar, or worn accelerator pedal.
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Old 04-08-2021, 09:12 AM   #8
simicrintz
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Default Re: 2004 DS throttle finally clicks after 50%

Quote:
Originally Posted by TahoeDawgZ71 View Post
Bad MCOR, Worn Drive-Bar, or worn accelerator pedal.
It is a new Mexican MCOR, new drive bar (from you, Sir!) but I have not looked at the accelerator pedal-DOH!!! Being lazy and not going to your site, do you have a replacement pedal, Dave?
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Old 04-09-2021, 01:21 AM   #9
aalbert77
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Default Re: 2004 DS throttle finally clicks after 50%

I fixed my worn pedal linkages on my 2004 DS carryall with a nylon bushing carried at Home Depot:
Internet #204276564 Model # 815028 Store SKU #595609
.0325 ID x 29/64 or 15/32 OD x 0.4-0.5" long

MCOR now switches at 1" down rather than half way down
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Old 04-09-2021, 08:55 AM   #10
simicrintz
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Default Re: 2004 DS throttle finally clicks after 50%

Thank you, aalbert!!
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