G2 broken resistor

[Jasonrkba]

Hello. My first post but I've been lurking for awhile. I have an older Yamaha G2 with a broken resistor. It's a clean break so I was wondering if it can be welded or will I have to replace it?

Thanks. Jason

[handtools]

Looks like a good excuse to convert to solid state!

[Jasonrkba]

Ive been buying batteries a pair at a time each payday and have bought 4 US2200 so far. Had plans to buy the last two next payday $100 a pop. Whole system has been rewired and other odds and ends its become a money pit on a tight budget. Im no cart pro but a fairly sharp guy. What would you guys say my most budget friendly option is here. My disabled wife is going to use this to get around on our farm.

[LukeL]

The best and safest option is a solid state conversion kit from cartsunlimited.net. Not the cheapest though. You can buy that resistor. I wouldn’t bother welding it.

[Jasonrkba]

There is a bit of sentimental value. It was my grandfather's who passed a few years ago and now the wife is dealing with chemo so it will be her way of getting out of the house. For the short term a resistor replacement seems the most reasonable option. Would you guys have a vendor you prefer or one's to avoid? My long term plan is to buy a newer cart in about a year or two.

I really appreciate the advice.
Thanks. Jason

[LukeL]

I’d check the site sponsors first and see if they have it. They will treat you right. If they don’t have it then check eBay or something like that.



Also, a G2 makes a great start for an upgrade if you decide you want to build off of that. Solid state Alltrax controllers, lift kits, high speed and torque motors, all sorts of fun stuff is available for the electric G2. [emoji1303]

[Jasonrkba]

Ebay has been a bust. I found one place on the net asking $176. I'll check with the sponsors and see what they have.

Thanks again

The conversion was $849.

[Lochlin]

Welding may melt the resistor. You are better off soldering (which might be what you meant?)

Another thing you can do is to solder a decent gauge wire, probably 8 or 10, across the break.

I am not sure what kind of resistor bank G2s used but any resistor bank from any cart will work in theory. You just have to be able to place the speed jumpers in the right places.

[Jasonrkba]

I was worried solder might not withstand the heat. It was getting very hot but i guess that could be due to the break. Here is a picture i took when I started working on it. I was bouncing a lot of ideas around. Possibly a M5 bolt coupling.

[Lochlin]

Originally Posted by Jasonrkba

I was worried solder might not withstand the heat. It was getting very hot but i guess that could be due to the break. Here is a picture i took when I started working on it. I was bouncing a lot of ideas around. Possibly a M5 bolt coupling.

If that break is 100% clean then the circuit isn't complete and there should be no heat at all. You may have some other wiring issue. That said, I know resistor carts very well but not the G2 specifically so I can't say for sure.

In most cases with resistor carts if things are "right" then the resistors only get warm and not hot. Certainly not hot enough to melt solder.