2000 Club Car DS 48 Volt Electrical issues

[jwmoon]

Have a 48 volt Club Car DS has 48 volt lighting kit, headlights, tail lights and brake lights. Light work every now and then, but fail to work continuously. In addition I can take a light tester and touch the uprights for the roof and detect a power source, Can almost touch any metal on the cart at it receives a power signal as well. Cleaned all battery connections, looked for loose or broken wires and replaced every issue found, still did not fix it. Can not find where or if cart grounds to the frame as it almost seems like a grounding issue? Not a fan of electrical issues? Help?

[Hunter450]

Its a process of elimination. I would start by finding the power source to your 12 volt accessories, disconnect the source and check to see if you still have voltage on the frame. If no voltage reading then you ruled out the higher voltage system.

[jwmoon]

I was able to remove the light kit wiring from the cart to eliminate it as the source of the power issue to the frame. Voltage was still present. Unhooked the battery indicator, power still present at the frame. Removed the Main positive and Main negative, still power at the frame.

I was able to get the headlights, taillights and horn to work by taking the grounds off the grounding strip on the frame under the driver's seat and placing them on to the battery Negative. Everything came on and works great. Still have power running into the frame somehow?

Now the negative battery cable runs back to the motor and down through a 6 inch long box that is in the frame well on the drivers side. It has 2 black wires that come out of it and they also ran to the grounding strip that the lights hooked too. Disconnect those and still have power source 39 Volts on all metal parts of the cart. Check wires cannot find any loose. Cleaned all battery cables and connections, still have power to frame at a loss currently.
It has a 16 v to 12 volt reducer on it currently. Everything working, does not seem to draw batteries down too much currently? Any suggestions

[NoleFan4Ever]

Originally Posted by jwmoon

Now the negative battery cable runs back to the motor and down through a 6 inch long box that is in the frame well on the drivers side. It has 2 black wires that come out of it and they also ran to the grounding strip that the lights hooked too.

That is your stock (OEM) 16v to 12v reducer

Originally Posted by jwmoon

Disconnect those and still have power source 39 Volts on all metal parts of the cart. Check wires cannot find any loose. Cleaned all battery cables and connections, still have power to frame at a loss currently.

Look at the positive side of the system and see if a cable has rubbed the sheath off somewhere or something going up to the main solenoid where it mounts to the frame.