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Old 07-08-2019, 04:50 PM   #1
Honu425
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Default 1997 Club Car DS 48 volt Forward/Reverse issue

I have a 97 Club Car DS. It's 48 volt. The past week I replaced the batteries and noted the reverse buzzer didn't work. Under the dash to check if I had pulled a wire off. Nope. Checked the other end of the wire and found the orange wire to the buzzer had broken off the microswitch; or rather the microswitch had broken. Went to local shop, bought new microswitches (all three), and at the same time bought a charge meter as this cart didn't have one.
Back at the house, installed the meter, pulled the F/R switch so I could change the microswitches (took pictures first). This switch doesn't look coroded but it is old. After I changed out all the microswitches and put things back together, .....
I now have a reverse buzzer, and can go forward. NO REVERSE. When I put it in reverse and work the throttle pedal, I can hear the solenoid going click, click. I took the F/R switch off again thinking I may have misaligned something, but that doesn't seem like a possibility. Frankly, I'm at a loss.
Would anyone have any suggestions?
Thanks in advance.
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Old 07-08-2019, 04:54 PM   #2
scottyb
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Default Re: 1997 Club Car DS 48 volt Forward/Reverse issue

On this cart 2 switches are 2 tab and 1 is a 3 tab - is that what you replaced them with? See my wiring document for our replacement switch attached, this will show where the wires go.
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Old 07-08-2019, 05:36 PM   #3
Honu425
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Default Re: 1997 Club Car DS 48 volt Forward/Reverse issue

Thanks for the response. Yes, this is exactly what I have. In fact, here's a photo of it.
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Old 07-08-2019, 06:26 PM   #4
Sergio
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Default Re: 1997 Club Car DS 48 volt Forward/Reverse issue

Another possibility is that the resistor inline with the black wire is broken.

You can by-pass the reverse reduced speed for testing.

Disconnect the Green and the White wires form micro-switch #3 and use an ATO style auto fuse to jump the two quick connectors together.

If the cart works in reverse, the resistor is likely broken.

If the cart still does not work in reverse, need to check the FNR and cables placements in case you disconnected them.
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Old 07-09-2019, 05:08 AM   #5
Honu425
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Default Re: 1997 Club Car DS 48 volt Forward/Reverse issue

Uh, WHAT resistor?
Seriously, there isn't one that I can find. I saw that in the drawings but I don't find one on my cart. Could it be located somewhere else?
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Old 07-09-2019, 05:21 AM   #6
Sergio
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Default Re: 1997 Club Car DS 48 volt Forward/Reverse issue

Did you connect the green and white wires to test?
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Old 07-09-2019, 08:16 AM   #7
Honu425
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Default Re: 1997 Club Car DS 48 volt Forward/Reverse issue

Sergio,
Thanks! I connected the Green and White wires. Now it goes in reverse.
But,
As I asked before, "What Resistor"? Where do I get one? Or do I really need one?
Any way it goes, Thanks much for the tip!
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Old 07-09-2019, 08:23 AM   #8
Sergio
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Default Re: 1997 Club Car DS 48 volt Forward/Reverse issue

If You follow the black wire into the harness a few inches, the resistor is right before the black wire splices with the white wire.

It is only needed if You want a reduced speed in reverse.

Replace it with a 5.1kΩ x 1/2 watt resistor like the one below:
https://www.mouser.com/ProductDetail...TCrgCxtI5k8%3D
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