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Old 08-26-2019, 03:17 PM   #1
Rlemon
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Join Date: Aug 2019
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Default Wires getting hot, melting plastic. 1991 club car.

Recently picked up a 91 electric club car 36 V. Bought it for something to run around the yard mostly. After more than just a few minutes of use, these wires are getting very hot to the point of smoking.
I’m decent with small engines, but know very little about electric motors. I’ve read dozens of threads and coming up empty.
Any thoughts would be appreciated.
See picture. It seems to mainly be the one circled, but I see signs of heat on the others
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Old 08-27-2019, 05:23 AM   #2
BBBHC
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Default Re: Wires getting hot, melting plastic. 1991 club car.

You can search around on here for wiring diagrams, or maybe someone who already has one will offer a link. I have one for a 92 DS, but I don't know if that is the same as a 91. If someone confirms that it's the same, I can send it to you.

Until then, I would suggest going through and cleaning up all the connections of your wires and cables. Looks like it has been a while since someone went through and cleaned up the corrosion and dirt. That is definitely not helping. Replace any wires that have signs of over heating and/or corrosion within the sheathing.
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Old 08-27-2019, 09:55 AM   #3
Lochlin
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Default Re: Wires getting hot, melting plastic. 1991 club car.

Yeah, your cart is almost certainly wired right or else it wouldn't run or something would have melting out by now. The most common cause of too much heat it from current being dissipated in wiring / components rather than into the speed of the cart. Think about what would happen if you parked your cart against a wall and hit the accelerator. Things would get real hot real fast.....but not for very long. All the heat from the current would melt everything inside due to not getting transferred to moving motor and wheels.

Clean things up nice and shiny and I bet your heat issues go away.
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Old 08-28-2019, 11:45 AM   #4
Rlemon
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Default Re: Wires getting hot, melting plastic. 1991 club car.

Those are sensible suggestions, I appreciate it.
I will start there, with a good cleaning this weekend
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