Incredible wiring

[Newbuggyboy]

So my wiring guy sent me some more wires today and refunded me money to pay for my wire loom. (I already had 1 long extra to do the F/R to Motor bypass, but wanted it nicer length. Same with solenoid to controller wire.) The wire loom wasn't that expensive. The thought is customer service #1.

What a pleasure to work with them.

[Newbuggyboy]

Today the wire loom arrives. I had one smallpiece of 1/2" inside diameter wire loom. It was a snug fit on my new 4 gauge wire. I'm curious to see if another brand of 1/2" inside diameter is also snug.

[Newbuggyboy]

Wire loom. I also bought a 5 pack roll of colored electrical tape. Red, black, etc... to put on the loom side for + or -. Other colors for controller, solenoid, and motor. Labeling them.

B = battery to battery
G = to motor (Go)
R = to controller

[Newbuggyboy]

Great wiring needs good connections.

So I cleaned the F/R and motor screws. I bought replacements screws and nuts for controler. Some new washers and nuts for F/R switch. Lastly, new nuts for the motor.

I usually do terminal and wire end cleaning with my dremel.

[Newbuggyboy]

I have never fired this baby up. I found a test plan I hope to use for my controller.

[Newbuggyboy]

I did some tedious cleaning of the 4 controller posts with my dremel. The 3 smaller posts required a nail file to sand/clean because they are so close together.

The large posts on the solenoid where cleaned with the lemon/baking soda solution. They were looking like a shiny new penny. I cleaned the top and bottom of the resistor leads, washers, and nuts. On the smaller solenoid posts I just clean the small wiring, washers, and nuts. I was afraid to mess with the diode. I do have a new resistor and diode, but I want to try the originals first before I change anything. I don't want to wire anything wrong.

Lastly, next to controller, I cleaned the micro switch's wires, small screws, washers, and micro switch itself.

All the sanding filings were blown away with a leaf blower before reassembling.

[Newbuggyboy]

I asked the seller about the wire and this was the word from my seller.

"correct on the 624 strands of bare copper and the 105c rated"

[Newbuggyboy]

I wasn't going to to the FNR switch, but I needed to paint near us so I removed it. I cleaned up the leads and screw inlets on micro switch.

I never looked at the controller lable until today. Curtis 275 amp

[Newbuggyboy]

They were hard to find but I got some brass screws and washers for my microswitches. I couldn't find any brass lock washers with external teeth.

[Newbuggyboy]

Replaced the microswitch's brass screws etc....

I clean the wire to/from the microswitches. Before I started that gray wire cover from FNR microswitch (with black & white wires) was grease black. Also look at above photo to compare blue + other wires.