Waterproofing a 2003 DS series drive

jsmith294 · 10-31-2017, 07:31 PM

Our 48V 2003 DS series drive seems hyper sensitive to water. If the cart is washed or if it is driven through a puddle that creates a lot of splash, it ceases to run until it dries out (for lack of a better turn). I'm not absolutely sure, but I get the impression the problem may be the F/R switch. Two questions:

Are there any other components on these carts sensitive to water that might be the culprit?
Is there anything I can do to waterproof the F/R switch?

Thanks!

TahoeDawgZ71 · 10-31-2017, 09:20 PM

It's the micro-switches on the F&R switch. The throttle signal that runs through switch #3 is such minimal resistance that the water affects it greatly. Lots of people put a splash guard over the back of the F&R switch and it seems to help the issue.

Dlab · 10-31-2017, 09:58 PM

Coating such connections with dielectric grease solved a similar issue I had.

jsmith294 · 11-01-2017, 06:19 AM

Quote:

Originally Posted by TahoeDawgZ71

It's the micro-switches on the F&R switch. The throttle signal that runs through switch #3 is such minimal resistance that the water affects it greatly. Lots of people put a splash guard over the back of the F&R switch and it seems to help the issue.

Dawg, is there an aftermarket part available, of to folks just rig something up? Thanks for the response and diagnosis.

jsmith294 · 11-01-2017, 06:21 AM

Quote:

Originally Posted by Dlab

Coating such connections with dielectric grease solved a similar issue I had.

I'll give this a try. Even if I add a shield later, it should help keep water and dirt out!

scottyb · 11-01-2017, 07:39 AM

I've seen a heavy flexible plastic sheet attached (rivet or screw) to the body so it hangs over the F&R and is simply flopped up when servicing the switch

TahoeDawgZ71 · 11-01-2017, 08:28 AM

The factory no longer sells it, but they did at one time. It was just a simple piece of rubber that was mounted to the bottom of the body support like Scottyb describes.

scottyb · 11-01-2017, 09:20 AM

I thought they were factory issue for a couple of years. Should be pretty easy to make-shift something. I see 20g clear vinyl for $6 a yd online

Sergio · 11-01-2017, 09:39 AM

If the Solenoid still "clicks" when the cart does not run, then it is likely water in the throttle micro-switch circuit as mentioned.

jsmith294 · 11-02-2017, 01:59 PM

Thanks for the great suggestions. I am proud that so many of the BGW Brain Trust weighed in with suggestions! I'll let you y'all know haw the enhancement turns out... and whether it works or not.

10-31-2017, 07:31 PM	#1
jsmith294 Gone Wild Join Date: Feb 2014 Posts: 156	Waterproofing a 2003 DS series drive Our 48V 2003 DS series drive seems hyper sensitive to water. If the cart is washed or if it is driven through a puddle that creates a lot of splash, it ceases to run until it dries out (for lack of a better turn). I'm not absolutely sure, but I get the impression the problem may be the F/R switch. Two questions: Are there any other components on these carts sensitive to water that might be the culprit? Is there anything I can do to waterproof the F/R switch? Thanks!
jsmith294 Gone Wild Join Date: Feb 2014 Posts: 156

10-31-2017, 09:20 PM	#2
TahoeDawgZ71 revolutiongolfcars.com Join Date: Mar 2010 Location: Golf Car Capital of The World... Augusta, Georgia Posts: 10,224	Re: Waterproofing a 2003 DS series drive It's the micro-switches on the F&R switch. The throttle signal that runs through switch #3 is such minimal resistance that the water affects it greatly. Lots of people put a splash guard over the back of the F&R switch and it seems to help the issue.

10-31-2017, 09:58 PM	#3
Dlab Gone Wild Join Date: May 2016 Posts: 373	Re: Waterproofing a 2003 DS series drive Coating such connections with dielectric grease solved a similar issue I had.
Dlab Gone Wild Join Date: May 2016 Posts: 373

11-01-2017, 07:39 AM	#6
scottyb Happy Carting Join Date: Dec 2007 Location: Southern California Posts: 73,419	Re: Waterproofing a 2003 DS series drive I've seen a heavy flexible plastic sheet attached (rivet or screw) to the body so it hangs over the F&R and is simply flopped up when servicing the switch

11-01-2017, 08:28 AM	#7
TahoeDawgZ71 revolutiongolfcars.com Join Date: Mar 2010 Location: Golf Car Capital of The World... Augusta, Georgia Posts: 10,224	Re: Waterproofing a 2003 DS series drive The factory no longer sells it, but they did at one time. It was just a simple piece of rubber that was mounted to the bottom of the body support like Scottyb describes.

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11-01-2017, 09:20 AM	#8
scottyb Happy Carting Join Date: Dec 2007 Location: Southern California Posts: 73,419	Re: Waterproofing a 2003 DS series drive I thought they were factory issue for a couple of years. Should be pretty easy to make-shift something. I see 20g clear vinyl for $6 a yd online

11-01-2017, 09:39 AM	#9
Sergio Gone Wild Join Date: Sep 2012 Location: Charlotte, NC Posts: 9,329	Re: Waterproofing a 2003 DS series drive If the Solenoid still "clicks" when the cart does not run, then it is likely water in the throttle micro-switch circuit as mentioned.

11-02-2017, 01:59 PM	#10
jsmith294 Gone Wild Join Date: Feb 2014 Posts: 156	Re: Waterproofing a 2003 DS series drive Thanks for the great suggestions. I am proud that so many of the BGW Brain Trust weighed in with suggestions! I'll let you y'all know haw the enhancement turns out... and whether it works or not.
jsmith294 Gone Wild Join Date: Feb 2014 Posts: 156

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