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Electric Club Car Electric DS, and Precedent golf cars |
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11-07-2015, 09:13 PM | #1 |
Not Yet Wild
Join Date: Nov 2015
Posts: 3
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1995 DS to MCOR4 Conversion - AM293201
I would like to try to give a little back to this forum as a way to repay for all of the information
that I have gained here over the years. So I thought I would post this information about how my brother and I installed a Pre-MCOR to MCOR4 Kit (AM293201) on our 1995 Club Car DS. Hopefully to help with anyone’s questions, here is some background information about the cart my brother and I bought several years ago for our hunt camp. Our cart is used almost exclusively in the woods and the serial number on our cart indicates that it is a 1995 Club Car DS (48 volt), also when purchased the cart appeared to be completely stock. The first upgrades that we made were to install a lift kit, large off road tires, GE D395 motor, HD F/R switch, high amperage solenoid, larger cables and an Alltrex AXE controller. We soon realized that the batteries needed replacing, so new batteries were installed. After a year or so of use, we were not happy with the throttle response of the stock Club Car stepped potentiometer. The cart would jump from one speed to the next and would not creep very well. So we first tried changing the values of the resistors in the stepped potentiometer. This helped and could have probably been made to work given time to determine the exact resistor values that we would need to give an acceptable throttle response. However, we really wanted a smoother and constantly variable throttle response. So we bought a PB-6 throttle potentiometer (0-5k). At first, it worked very well and we thought we had solved our throttle issue. However, the PB-6 is not sealed very well and after a year or so, oxidization the PB-6’s internal potentiometer would cause the cart to jerk and jump. This was very dangerous, especially in the woods or on rough terrain. Placing the cart in neutral and pumping the gas pedal would “clean” the potentiometer and the cart would operate great for a short period of time. However, this got old really quickly and, after a few close calls, it was obvious that a new solution was in order. Meanwhile, someone else at the camp had purchase a 1996 Club Car, which had a newer pedal design that included a MCOR. He asked us to upgrade his cart with the same off-road items we had on our cart. After the power and lift upgrades, his cart ran great and his MCOR continued to operate smoothly. So, we ordered the Club Car #AM293201 - MCOR 4 Conversion Kit to replace the PB-6 throttle potentiometer on our cart. I hope this is of some help to someone.... Sorry this is so long and the files are so big... First real post to the forum... |
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11-09-2015, 05:58 PM | #2 |
Not Yet Wild
Join Date: Nov 2015
Posts: 3
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Re: 1995 DS to MCOR4 Conversion - AM293201
When the ZIP files that are attached to the above post are extracted, you will have the detailed PDF conversion document for installing the AM293201 MCOR4 conversion on a 1995 style pedal group as seen below.
The PDF document was way too large to upload as a PDF, so I had to divide it up and compress it to meet the file upload requirements of the forum... Thanks for looking... |
02-24-2017, 01:01 PM | #3 |
Not Yet Wild
Join Date: Jan 2017
Location: Dakota Territory
Posts: 15
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Re: 1995 DS to MCOR4 Conversion - AM293201
Does anyone else have the .PDF? I cannot get the zip files opened. If so PM me, thanks
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02-24-2017, 05:30 PM | #4 |
revolutiongolfcars.com
Join Date: Mar 2010
Location: Golf Car Capital of The World... Augusta, Georgia
Posts: 10,224
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Re: 1995 DS to MCOR4 Conversion - AM293201
Nice work! I've done this several times and it's possible, but it's not a bolt-on kit like it would be on a 1996 and newer cart. Very clean install! I like it.
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08-08-2019, 08:51 AM | #5 |
Not Yet Wild
Join Date: Aug 2019
Location: Michigan
Posts: 12
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Re: 1995 DS to MCOR4 Conversion - AM293201
Thank you, your post was very helpful. I tried to do the same but ran into an issue. I have Later 1995 CC DS with a bad pot. Ordered AM293101 instead of AM293201 because everything I read said it should work. I made an aluminum bracket to support the the pedal rod. I cut plug ends & wired it straight through (all wires match color perfectly). All I get is a click.. The switch in the mcor works. I reconnected the pot to the white, yellow & purple wires, cart goes (only full speed due to bad pot). I’m starting to think I needed AM293201, does this sound right?. At this point, all I’m missing is the wire harness & cannot afford to buy another kit. Does anyone know how to make the wire harness? Do you think this is my problem? Any help would greatly be appreciated.. I’m building this with my son & have already gone way over budget. First post ever on the internet, thanks for welcoming me.
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08-08-2019, 09:06 AM | #6 | |
revolutiongolfcars.com
Join Date: Mar 2010
Location: Golf Car Capital of The World... Augusta, Georgia
Posts: 10,224
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Re: 1995 DS to MCOR4 Conversion - AM293201
Quote:
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08-08-2019, 09:51 AM | #7 |
Not Yet Wild
Join Date: Aug 2019
Location: Michigan
Posts: 12
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Re: 1995 DS to MCOR4 Conversion - AM293201
Thanks for the reply. The rod included in the kit seemed to fit properly. When pedal pressed, it rotates about a third of a circle, is that enough? I will definitely check that when I get home. I appreciate the help!
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08-08-2019, 06:42 PM | #8 |
revolutiongolfcars.com
Join Date: Mar 2010
Location: Golf Car Capital of The World... Augusta, Georgia
Posts: 10,224
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Re: 1995 DS to MCOR4 Conversion - AM293201
There is an extra barb on the new style pivot rod, intended for holding the drive bar in place. On an old style car, the pivot rod doesn't have this barb and the drive bar can be very sloppy or fall off.
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08-08-2019, 06:49 PM | #9 |
Not Yet Wild
Join Date: Aug 2019
Location: Michigan
Posts: 12
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Re: 1995 DS to MCOR4 Conversion - AM293201
You”re right, checked the rod & it’s not perfect but it still moves enough to turn the mcor. I lifted the cart, connected everything & turned the mcor with a screwdriver (I know, not smart). I got desperate... anyway, still nothing but clicks. I’m going to try another mcor tomorrow, I think this one is bad. Then I’ll hv to solve the pedal rod problem lol. Thanks & I’ll keep you posted.
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08-08-2019, 07:55 PM | #10 |
revolutiongolfcars.com
Join Date: Mar 2010
Location: Golf Car Capital of The World... Augusta, Georgia
Posts: 10,224
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Re: 1995 DS to MCOR4 Conversion - AM293201
Did you check the throttle signal where it goes into the controller like we talked about on the phone? Meter set to 20k ohms, unplug yellow wire and green wire from controller. Check resistance on these wires. Should be approximately 5000 - 0 ohms from no throttle to full throttle.
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