99 CC 48v hot battery cable

[charman]

99 club car series 48v stock, nothing fancy
the cable from motor to F/R switch gets burning hot even on short drive, end of street and back. will burn fingers if you touch cable and has melted copper contacts in F/R switch. as far as i know the cart was converted by a cart dealer in sun city when it was new. any ideas because this knucklehead (me) is not smart enough to figure it out on my own.

[charman]

the cable from the motor to the F/R switch is the Orange cable on the cc wiring diagram. It connects to the FWD side of the F/R switch. the copper contact on the FWD side gets hot and melts to the copper plate in the switch eventually causing a void btw the two and poor contact. if i "jimmy" the switch it will again make contact and work. The Reverse side works fine and doesn't get hot. It is a heavy duty switch i bought from a cart repair shop locally and it melted within the first few trips around the neighborhood. i guess the true source of the problem is why the cable gets so hot. its been documented i know nothing when it comes to carts. suggestions will be much appreciated.

[Sergio]

Heat is generated when current passes thru a point of high resistance in the circuit.

Since you already replaced the FNR switch, the most likely problem is a bad crimped connection or corroded cable near the orange cable lug.

Also, make sure you have the correct sized cable lug hole in case someone has already replaced the cable lug but used the wrong size. That will cause a poor connection.

[drbihlmeier]

Same thing was happening to my cart wires. Finally reverse just stopped working. Was told on here I needed a heavy duty switch and new wires. Ordered from carts unlimited. Will update my thread once I receive switch and install. Took apart the switch I had, and plastic was melted all around the copper. So I guess replace the Orange wire and see what happens.

[Swan]

what ga cables are they ? , if there stock you should consider go to 4 ga