Loose wires on FNR switch

[cpbrock3]

I'm trying to help my parents get their golf cart going again. I'm new to these things so I'll post what I know and see if we can figure this thing out without throwing parts at it.

The plate in the glove box says J198. There is not a switch for tow/maint. on the controller cover. From what I read, I guess that means I'm working with a '98 TXT 36 volt series cart. Everything on this cart is stock.

My dad says that when it was still working, the seat would get warm. Also, when you pushed the pedal in forward gear it would only sometimes go. When it would go, it wouldn't be a smooth acceleration but full throttle. There is also no sound coming from the reverse buzzer.

I took off the covers to investigate and found a red wire and a black wire hanging loose off of the FNR switch. The plate also looks like it has seen some heat. Everything else seems to be fine. Can these wires be hooked up again to get this thing rolling or should the whole FNR switch be replaced?

Here are some pictures of the loose wires. There are also two small bolts going through the plate that have black things on them. I'm not sure if those are the connections that the wires came loose from. I can take more pictures if it will help.
http://picasaweb.google.com/cpbrock3...NPOnuL22-7zVg#

[rusty1]

it has seen a lot of heat i had one just like this i finally replaced it with a new one to get the problem fixed but they can be rebuilt

[dougmcp]

Originally Posted by cpbrock3

Can these wires be hooked up again to get this thing rolling or should the whole FNR switch be replaced?

Yes you can reinstall the small wires but be sure to cut them back to where the wire is flexible or replace them completely. You are getting heat generated from a poorly contacting FNR switch and it should also be replaced with a stock one.
They are around $100 from our sponsors http://www.buggiesgonewild.com/site-sponsors.php

[cpbrock3]

I'm thinking that these wires went to the reverse buzzer that was mounted with plastic clips that eventually melted and broke and fell off. Doesn't seem like a missing buzzer would be the reason for the cart not working. Is there a way to test the other wires on this switch to see if it is working?

It's already broken, but I don't want to break it anymore if at all possible.

[Fleck]

Originally Posted by cpbrock3

I'm thinking that these wires went to the reverse buzzer that was mounted with plastic clips that eventually melted and broke and fell off. Doesn't seem like a missing buzzer would be the reason for the cart not working. Is there a way to test the other wires on this switch to see if it is working?

It's already broken, but I don't want to break it anymore if at all possible.

I agree that the are the wires for the M.I.A. reverse buzzer. Like Doug Cp said; That thing has seen Alot of heat and should be replaced. I just rebiult mine for $45.00. Parts from our sponsors.

[dougmcp]

Originally Posted by cpbrock3

I'm thinking that these wires went to the reverse buzzer that was mounted with plastic clips that eventually melted and broke and fell off. Doesn't seem like a missing buzzer would be the reason for the cart not working. Is there a way to test the other wires on this switch to see if it is working?

I believe you need the whole circuit to get power to the controller. Here is the wiring for my cart which should be similar to yours.

[cpbrock3]

The whole thing is going to get replaced because the nuts that hold the wires pretty much welded themselves on. So the wires are going to get replaced as well. I was going to stop by the local auto zone and pick up a roll of wire and make my own wires. Any suggestions on gauge or type of wire to replace the old ones?

[dougmcp]

I'm guessing the wire size is around 14ga; it's only control wire so it's not a huge concern.
I would keep the original wire colors as it makes trouble shooting for you and others much easier if something goes bad later.
That means you'll need red, blue, white, orange and black, maybe brown and yellow too. I'd just get the small packs as you don't need big rolls of wire for this.

[cpbrock3]

I hope they appreciate the work I'm about to do for them. I told my dad about upgrading to the 48 volts while I'm in there. Should have waited till mom wasn't around cause she didn't like the idea. It's not like she'll ever know though...

How do I go from 'Not yet wild' to 'Gone Wild' ?

[dougmcp]

You have a perfect cart to upgrade to 48v, it will add 5mph to your speed and give you more power to boot.
What is the model number of your motor?

What you will probably need for the conversion:
48v controller if you don't already have a 36v-48v model, should be 400 amp.
4ga cables
48v solenoid
48v charger
2 extra 6v batteries or 6x8v batteries.