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Electric EZGO Electric EZ GO Marathon, Medalist, TXT and RXV.



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Old 03-15-2017, 06:24 AM   #1
noslofivoh
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Yamaha
 
Join Date: Nov 2012
Location: Commerce, GA
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Default Battery cable replacement

I am looking to replace my battery cables with 2awg flexible welding cable. I have access to as much as I need and the terminals. My question is what all cables need to be replaced to be beneficial- I know the batteries but how about the ones to the motor and controller? Also how much do I need to get the job done- 50ft, 100ft? It is going to be a slow project as I work on my cart a little at a time. If it helps, its a 2000 TXT.
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Old 03-15-2017, 06:51 AM   #2
mutant
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E-Z-GO
 
Join Date: Aug 2014
Location: fletcher,nc
Posts: 601
Default Re: Battery cable replacement

i have the same model-mine is series drive.....you must replace them all,all big cables...
i used 600 strand count cable-made my own copper ends and soldered them myself.
believe i bought a 100'roll of ground cable and still have a little left over-not sure the footage used though....
if i did it over-i would just buy a set from scottyB at carts unlimited-mine work flawlessly but his are awesome and i would spend my time doing something else...
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Old 03-15-2017, 07:14 AM   #3
scottyb
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Location: Southern California
Posts: 73,356
Default Re: Battery cable replacement

The battery pack amperage goes through all of the cables to power the motor. Anytime the motor is running high amperage is flowing through all the cables. Cut one in half and the cart stops. Think of this flow like cars on a freeway. If traffic (amperage) is flowing down the 4 lane road and suddenly the road is reduced to 2 lanes the flow is impeded and delivery is restricted.
All the cables should be the same size. While there is no harm in using really big cable, 2g welding lead is all that is needed.
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Old 03-15-2017, 08:42 AM   #4
JoeBleaux
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Default Re: Battery cable replacement

Did you happen to notice my post on this very subject from, ahem, last night? Replace them all with the same size cable esp if you have unlimited access to the cable components. You didn't mention voltage of your cart, but on a 36v TXT, 25 feet of cable and 2 feet each of red and black heatshrink will more than do it. If yours is a 48v, measure the existing cables and add a little for an oops factor.
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Old 03-15-2017, 08:57 AM   #5
JoeBleaux
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Default Re: Battery cable replacement

PS - a cable-building tip IF YOU KNOW WHERE EVERY CABLE GOES or have a schematic at hand: simply remove all the cables and use them as successive length templates on the bulk cable, marking each "in line" with the next and then, make all the cuts. Then, strip all ends, crimp/solder all terminals, then heatshrink all ends (another tip - get the 2x shrink, adhesive type, and it can go on after the terminal lugs are on), let cool and install.

I built a full set (unfortunately, a mismatched set with 2 different cable gauges, in 2 different sessions, which as soon as I pick up another box of terms I'll have to correct) in about 20 minutes total using a hand cutter and whack-a-mole crimper.
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